Porous shaped carbon products

ABSTRACT

Shaped porous carbon products and processes for preparing these products are provided. The shaped porous carbon products can be used, for example, as catalyst supports and adsorbents. Catalyst compositions including these shaped porous carbon products, processes of preparing the catalyst compositions, and various processes of using the shaped porous carbon products and catalyst compositions are also provided.

REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application Ser. No. 62/247,721, filed Oct. 28, 2015, the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to shaped porous carbon products and processes for preparing these products. The shaped porous carbon products can be used, for example, as catalyst supports, chromatographic support material, filtration media and adsorbents. The present invention also relates to catalyst compositions including these shaped porous carbon products, processes of preparing the catalyst compositions, and various processes of using the shaped porous carbon products and the catalyst compositions.

BACKGROUND OF THE INVENTION

Carbon is a material that can be deployed as a catalyst support or adsorbent. The most commonly used carbon based supports for chemical catalysis are activated carbons exhibiting high specific surface areas (e.g., over 500 m²/g). Preparing activated carbon requires activating a carbonaceous material such as charcoal, wood, coconut shell or petroleum-sourced carbon black either by a chemical activation, such as contacting with an acid at high temperatures, or by steam activation. Both methods of activation produce high concentrations of micropores and consequently higher surface areas. Depending upon the source of the carbonaceous material, the resultant activated carbons may have a high residual content of inorganic ash and sulfur, and possibly oxygen or nitrogen-containing functional groups at the surface. Activated carbons are thought to possess an optimum support structure for catalytic applications as they enable good dispersion of catalytically active components and effective adsorption and reaction of chemical reagents at the catalyst surface.

In recent years, there has been a growing interest in using biorenewable materials as a feedstock to replace or supplement crude oil. See, for example, Klass, Biomass for Renewable Energy, Fuels, and Chemicals, Academic Press, 1998. This publication and all other cited publications are incorporated herein by reference. One of the major challenges for converting biorenewable resources such as carbohydrates (e.g., glucose derived from starch, cellulose or sucrose) to current commodity and specialty chemicals is the selective removal of oxygen atoms from the carbohydrate. Approaches are known for converting carbon-oxygen single bonds to carbon-hydrogen bonds. See, for example, U.S. Pat. No. 8,669,397, which describes a process for the conversion of glucose to adipic acid via the intermediate glucaric acid. One challenging aspect associated with the catalytic conversions of highly functionalized biorenewably-derived molecules and intermediates is reaching the high levels of catalytic activity, selectivity and stability necessary for commercial applications. With respect to catalytic activity and selectivity, highly functionalized, biorenewably-derived molecules and intermediates derived from carbohydrates (e.g., glucose and glucaric acid) are non-volatile and must therefore be processed as solutions in the liquid phase. When compared to gas phase catalytic processes, liquid phase catalytic processes are known to suffer from lower productivities because liquid to solid (and gas to liquid to solid) diffusion rates are slower than gas to solid diffusion rates.

Another challenging aspect associated with the catalytic conversion of highly functionalized biorenewably-derived molecules and intermediates is the use of chemically aggressive reaction conditions. For example, U.S. Pat. No. 8,669,397 describes catalytic conversion steps performed at elevated temperatures in the presence of polar solvents such as water and acetic acid. Polar solvents are typically required for the dissolution of non-volatile, highly-functionalized molecules such as glucose and glucaric acid, and elevated temperatures are required for productive and affordable catalytic conversion steps for commodity chemical applications. Therefore, a significant challenge associated with the catalytic conversion of highly functionalized biorenewably-derived molecules and intermediates is catalyst stability. Long term catalyst stability is a necessity for commodity chemical production, meaning that the catalyst must be stable, productive, and selective under reaction conditions for long periods.

The challenges associated with the development of industrial shaped catalysts, especially in the conversion of biorenewably-derived molecules and intermediates, are a) high productivity and selectivity consistent with an economically viable catalyst at industrial scale, b) mechanical and chemical stability of the shaped catalyst support and c) retention of the catalytically active components by the support and the avoidance of leaching of the catalytically active components into a polar solvent reaction medium. There remains a need for industrially scalable, highly active, selective and stable catalyst supports and catalyst compositions that can satisfy these challenges.

SUMMARY OF THE INVENTION

Briefly, in various aspects, the present invention is directed to processes for preparing shaped porous carbon products. In accordance with various embodiments, processes for preparing a shaped porous carbon product comprise mixing a carbonaceous material and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

In accordance with other embodiments, processes for preparing a shaped porous carbon product comprise mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises at least two heating stages that are each maintained at an approximately constant temperature and the temperature of each stage differs by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C.

In accordance with further embodiments, processes for preparing a shaped porous carbon product comprise mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises: (1) a first heating stage where the shaped carbon composite is heated at a first temperature; and (2) a second heating stage where the shaped carbon composite is heated at a second temperature and wherein the first and second temperature are each approximately constant and the second temperature is greater than the first temperature by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C.

Other embodiments are directed to processes for preparing a shaped porous carbon product that comprise mixing water, a carbonaceous material, and an organic binder to form a carbonaceous material mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbonaceous material mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises a continuous rotary kiln.

Further embodiments are directed to processes for preparing a shaped porous carbon product that comprise mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; drying the shaped carbon composite at a temperature from about 90° C. to about 150° C., from about 100° C. to about 150° C., or from about 100° C. to about 140° C., wherein the water content of the shaped carbon composite after drying is no greater than about 25 wt. %, no greater than about 20 wt. %, no greater than about 15 wt. %, no greater than about 12 wt. %, no greater than about 11 wt. %, or no greater than about 10 wt. %; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

Still further embodiments are directed to processes for preparing a shaped porous carbon product that comprise mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a water soluble polymer, wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity of no greater than about 500 mPa·s, no greater than about 400 mPa·s, no greater than about 300 mPa·s, no greater than about 200 mPa·s, no greater than about 100 mPa·s, no greater than about 75 mPa·s, or no greater than about 50 mPa·s at 25° C. and/or the water soluble polymer has a number average molecular weight (M_(n)) that is no greater than about 50,000 g/mol, no greater than about 40,000 g/mol, no greater than about 30,000 g/mol, no greater than about 25,000 g/mol, or no greater than about 20,000 g/mol; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

Further aspects of the present invention are directed to shaped porous carbon products. In accordance with various embodiments, the shaped porous carbon products comprise carbon black and a carbonized binder comprising a carbonization product of an organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 5 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and a carbon black content of at least about 35 wt. %, and wherein the shaped porous carbon product has improved wettability as compared to shaped porous carbon product control 1 as described herein.

In accordance with other embodiments, the shaped porous carbon products comprise a carbon agglomerate comprising a carbonaceous material wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 5 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and wherein the shaped porous carbon product has improved wettability as compared to shaped porous carbon product control 1 as described herein.

Aspects of the present invention are also directed to various catalyst compositions and methods for preparing the catalyst compositions. For example, a catalyst composition according to various embodiments comprises a shaped porous carbon product as a catalyst support and a catalytically active component or precursor thereof at a surface of the support. Another catalyst composition comprises a shaped porous carbon support and a catalytically active component or precursor thereof comprising platinum and gold at a surface of the support. Still another catalyst composition comprises a shaped porous carbon support and a catalytically active component or precursor thereof comprising platinum and rhodium at a surface of the support. Methods of preparing a catalyst composition in accordance with the present invention comprise depositing a catalytically active component or precursor thereof on a shaped porous carbon product.

In other aspects, the present invention is further directed to various processes of using the shaped porous carbon products and the catalyst compositions. One process in accordance with the present invention is for the catalytic conversion of a reactant comprising contacting a liquid medium comprising the reactant with a catalyst composition of the present invention. Other processes include the selective oxidation of an aldose to an aldaric acid and the selective hydrodeoxygenation of aldaric acid or salt, ester, or lactone thereof to a dicarboxylic acid. Moreover, the present invention is directed to methods of preparing a reactor vessel for a liquid phase catalytic reaction. The methods comprise charging the reactor vessel with a catalyst composition of the present invention.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a scanning electron microscopy image of the cross-section of a sample of the catalyst extrudate prepared with MONARCH 700 carbon black.

FIG. 2 provides a magnified view of one of catalyst extrudate cross-sections of FIG. 1.

FIG. 3 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a raw MONARCH 700 carbon black material.

FIG. 4 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a fresh catalyst extrudate including the MONARCH 700 carbon black material.

FIG. 5 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a catalyst extrudate including the MONARCH 700 carbon black material following 350 hours of use.

FIG. 6 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using MONARCH 700 carbon black and a glucose/hydroxyethyl cellulose binder.

FIG. 7 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Sid Richardson SC159 carbon black and a glucose/hydroxyethyl cellulose binder.

FIG. 8 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Sid Richardson SC 159 carbon black and a glucose/hydroxyethyl cellulose binder which has been exposed to oxygen at 300° C. for 3 hours.

FIG. 9 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Asbury 5368 carbon black and a glucose/hydroxyethyl cellulose binder.

FIG. 10 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an activated carbon extrudate of Sud Chemie G32H-N-75.

FIG. 11 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an activated carbon extrudate of Donau Supersorbon K4-35.

FIG. 12 presents the pore size distribution for an extrudate using Sid Richardson SC159 carbon black and a glucose/hydroxyethyl cellulose binder measured by mercury porosimetry.

DETAILED DESCRIPTION

The present invention generally relates to shaped porous carbon products and processes for preparing these products. The shaped porous carbon products can be used, for example, as catalyst supports, chromatographic support material, filtration media, adsorbents, and the like. The present invention also relates to catalyst compositions including these shaped porous carbon products, processes of preparing the catalyst compositions, and various processes of using the shaped porous carbon products and catalyst compositions.

The present invention provides shaped porous carbon products that exhibit high mechanical strength and are resistant to crushing and attrition during use. Further, the shaped porous carbon products possess excellent chemical stability to reactive solvents such as acids and other polar solvents even at elevated temperatures. The shaped porous carbon products are highly suited for liquid phase catalytic reactions because they can provide for effective mass transfer of compounds having relatively large molecular volumes to and away the surface of the support.

The present invention also provides processes for preparing the shaped porous carbon products. The shaped porous carbon products can be prepared from inexpensive and readily available materials which advantageously improves process economics. Furthermore, the disclosed processes are suited for preparation of robust, mechanically strong, shaped porous carbon products through the use of water soluble organic binders. These processes avoid the use of organic solvents that require special handling and storage.

The present invention further provides catalyst compositions comprising the shaped porous carbon products as catalyst supports and processes for preparing these catalyst compositions. The shaped porous carbon products exhibit a high degree of retention of the catalytically active component(s) of the catalyst compositions, which beneficially avoids or reduces the amount of catalytically active material leached into a liquid phase reaction medium. Also, the catalyst compositions possess a high degree of stability which is necessary for commodity chemical production.

Further, the shaped porous carbon products of the present invention can be highly wettable, which improves catalyst preparation methods when these products are used as catalyst supports. A high wetting rate is advantageous for catalyst preparation, especially wet catalyst preparation techniques, because it provides for rapid and uniform contact between the solution containing the catalytically active component or precursor thereof and the pore surfaces of the support. As a result, the catalytically active component or precursor thereof is more dispersed on the support, which can lead to higher production of catalyst materials. Furthermore, a fast wetting rate limits contact time under mixing conditions which can decrease the potential for formation of catalyst fines through attrition and abrasion of the catalyst support under mixing conditions.

The present invention also provides processes utilizing shaped porous carbon products and catalyst compositions, such as for the conversion of biorenewably-derived molecules and intermediates for commodity applications (e.g., the selective oxidation of glucose to glucaric acid) or for applications requiring adsorption of compounds having relatively large molecular volumes. Surprisingly, it has been found that the shaped porous carbon products exhibit a superior mechanical strength (e.g., mechanical piece crush strength and/or radial piece crush strength), and the use of catalyst compositions comprising the shaped porous carbon products of the present invention provides unexpectedly higher productivity, selectivity and/or yield in certain reactions when compared to similar catalysts compositions with different catalyst support materials.

Shaped Porous Carbon Products and Methods of Preparation

Generally, the shaped porous carbon products of the present invention are prepared with a carbonaceous material. The term, “carbonaceous material” is used herein to refer to elemental carbon that is in the form of graphite or an amorphous form of carbon, and combinations thereof. Specific examples of amorphous carbonaceous materials include activated carbon, carbon black, and combinations thereof. The choice of carbonaceous material employed may depend on the properties of the shaped porous carbon product desired. For example, when a relatively low porosity, low specific surface area product is desired, carbon black is typically employed. When a relatively high porosity, high specific surface area product is desired, activated carbon is typically utilized. In certain applications, e.g., when a highly electrically-conductive product is desired, graphite may be employed as the carbonaceous material.

In some embodiments, the shaped porous carbon products of the present invention are prepared with carbon black as the carbonaceous material. Carbon black materials include various subtypes including acetylene black, conductive black, channel black, furnace black, lamp black and thermal black. The primary processes for manufacturing carbon black are the furnace and thermal processes. Generally, carbon black is produced through the deposition of solid carbon particles formed in the gas phase by combustion or thermal cracking of petroleum products. Carbon black materials are characterized by particles with diameters in the nanometer range, typically from about 5 to about 500 nm. Carbon black materials can be supplied as powders or agglomerates of carbon black particles (e.g., pellets and granular forms). Some carbon black agglomerates have a particle size in the range of from about 100 μm to about 1000 μm.

Carbon black materials also have much lower surface areas, a higher concentration of mesopores, and lower ash and sulfur content when compared to activated carbons. Carbon black materials are deployed commercially for many applications such as fillers, pigments, reinforcement materials and viscosity modifiers. However, due to their very low surface areas, carbon black materials are not typically used as supports for chemical catalysis or adsorbents. Low surface area carbon black materials can be considered non-optimal as support structures for catalytic applications because low surfaces areas are considered detrimental to effective dispersion of catalytically active components leading to poor catalytic activity.

As noted, activated carbons are thought to possess an optimum support structure for catalytic applications as they enable good dispersion of catalytically active components and effective adsorption and reaction of chemical reagents at the catalyst surface. In contrast, the use of carbon black as a catalyst support has been limited. In order to utilize carbon blacks as supports for chemical catalysis, several groups have reported methods to modify carbon black materials. Reported modifications are centered on methods to increase the surface area of the carbon black materials. U.S. Pat. No. 6,337,302 describes a process to render a “virtually useless” carbon black into an activated carbon for commodity applications. U.S. Pat. No. 3,329,626 describes a process to convert carbon black materials with surface areas from 40-150 m²/g by steam activation into activated carbons with surface areas up to around 1200 m²/g.

Notwithstanding these teachings, it has been surprisingly discovered that certain carbon black materials exhibiting particular combinations of characteristics such as surface area, pore volume, and pore diameter are highly effective for use in shaped porous carbon catalyst supports for catalytic reactions including liquid and mixed phase reaction mediums. The shaped porous carbon products of the present invention can be shaped into mechanically strong, chemically stable, robust forms that can reduce resistance to liquid and gas flows, withstand desired process conditions, and provide for long term, stable catalytic operation. These shaped porous carbon products provide high productivity and high selectivity during long term continuous flow operation under demanding reaction conditions including liquid phase reactions in which the catalyst composition is exposed to reactive solvents such as acids and water at elevated temperatures.

The carbonaceous material typically constitutes a large portion of the shaped porous carbon product of the present invention. As such, the carbonaceous material (e.g., carbon black) content of the shaped porous carbon product is at least about 35 wt. % or more such as at least about 40 wt. %, at least about 45 wt. %, at least about 50 wt. %, at least about 55 wt. %, at least about 60 wt. %, at least about 65 wt. %, or at least about 70 wt. % on a dry weight basis. In various embodiments, the carbonaceous material (e.g., carbon black) content of the shaped porous carbon product is from about 35 wt. % to about 80 wt. %, from about 35 wt. % to about 75 wt. %, from about 40 wt. % to about 80 wt. %, or from about 40 wt. % to about 75 wt. % on a dry weight basis. The carbonaceous material content of the shaped porous carbon product is determined by the following formula: (Weight of carbonaceous material used to prepare the shaped porous carbon product)/(Dry weight of the shaped porous carbon product)×100%

When carbon black is used as the carbonaceous material, the carbon black materials used to prepare a shaped porous carbon product of the present invention typically have a BET specific surface area that is at least about 5 m²/g, at least about 7 m²/g, or at least about 10 m²/g. For example, the BET specific surface can be in the range of from about 5 m²/g to about 500 m²/g, from about 5 m²/g to about 350 m²/g, from about 5 m²/g to about 250 m²/g, from about 5 m²/g to about 225 m²/g, from about 5 m²/g to about 200 m²/g, from about 5 m²/g to about 175 m²/g, from about 5 m²/g to about 150 m²/g, from about 5 m²/g to about 125 m²/g, from about 5 m²/g to about 100 m²/g, from about 7 m²/g to about 500 m²/g, from about 7 m²/g to about 350 m²/g, from about 7 m²/g to about 250 m²/g, from about 7 m²/g to about 225 m²/g, from about 7 m²/g to about 200 m²/g, from about 7 m²/g to about 175 m²/g, from about 7 m²/g to about 150 m²/g, from about 7 m²/g to about 125 m²/g, from about 7 m²/g to about 100 m²/g, from about 10 m²/g to about 500 m²/g, from about 10 m²/g to about 350 m²/g, from about 10 m²/g to about 250 m²/g, from about 10 m²/g to about 225 m²/g, from about 10 m²/g to about 200 m²/g, from about 10 m²/g to about 175 m²/g, from about 10 m²/g to about 150 m²/g, from about 10 m²/g to about 125 m²/g, or from about 10 m²/g to about 100 m²/g. In various embodiments, the BET specific surface area of the carbon black is in the range of from about 20 m²/g to about 500 m²/g from about 20 m²/g to about 350 m²/g, from about 20 m²/g to about 250 m²/g, from about 20 m²/g to about 225 m²/g, from about 20 m²/g to about 200 m²/g, from about 20 m²/g to about 175 m²/g, from about 20 m²/g to about 150 m²/g, from about 20 m²/g to about 125 m²/g, or from about 20 m²/g to about 100 m²/g, from about 25 m²/g to about 500 m²/g, from about 25 m²/g to about 350 m²/g, from about 25 m²/g to about 250 m²/g, from about 25 m²/g to about 225 m²/g, from about 25 m²/g to about 200 m²/g, from about 25 m²/g to about 175 m²/g, from about 25 m²/g to about 150 m²/g, from about 25 m²/g to about 125 m²/g, from about 25 m²/g to about 100 m²/g, from about 25 m²/g to about 75 m²/g, from about 30 m²/g to about 500 m²/g, from about 30 m²/g to about 350 m²/g, from about 30 m²/g to about 250 m²/g, from about 30 m²/g to about 225 m²/g, from about 30 m²/g to about 200 m²/g, from about 30 m²/g to about 175 m²/g, from about 30 m²/g to about 150 m²/g, from about 30 m²/g to about 125 m²/g, from about 30 m²/g to about 100 m²/g, or from about 30 m²/g to about 70 m²/g. The specific surface area of carbon black materials is determined from nitrogen adsorption data using the Brunauer, Emmett and Teller (BET) Theory. See J. Am. Chem. Soc. 1938, 60, 309-331 and ASTM Test Methods ASTM 3663, D6556, or D4567 which are Standard Test Methods for Total and External Surface Area Measurements by Nitrogen Adsorption and are incorporated herein by reference.

The carbon black materials generally have a mean pore diameter greater than about 5 nm, greater than about 10 nm, greater than about 12 nm, or greater than about 14 nm. In some embodiments, the mean pore diameter of the carbon black materials used to prepare the shaped porous carbon product is in the range of from about 5 nm to about 100 nm, from about 5 nm to about 70 nm greater, from 5 nm to about 50 nm, from about 5 nm to about 25 nm, from about 10 nm to about 100 nm, from about 10 nm to about 70 nm greater, from 10 nm to about 50 nm, or from about 10 nm to about 25 nm. Such mean pore diameters enable effective transport of reactant molecules possessing large molecular volumes (such as biorenewably-derived molecules with 6-carbon atom frameworks) into and out of the pore structure of the catalytically active surface, thereby enabling enhanced activity.

The carbon black materials that can be used to prepare the shaped porous carbon products of the present invention also generally have specific pore volumes greater than about 0.1 cm³/g, greater than about 0.2 cm³/g, or greater than about 0.3 cm³/g. The specific pore volume of the carbon black materials can range from about 0.1 cm³/g to about 1 cm³/g, from about 0.1 cm³/g to about 0.9 cm³/g, from about 0.1 cm³/g to about 0.8 cm³/g, from about 0.1 cm³/g to about 0.7 cm³/g, from about 0.1 cm³/g to about 0.6 cm³/g, from about 0.1 cm³/g to about 0.5 cm³/g, from about 0.2 cm³/g to about 1 cm³/g, from about 0.2 cm³/g to about 0.9 cm³/g, from about 0.2 cm³/g to about 0.8 cm³/g, from about 0.2 cm³/g to about 0.7 cm³/g, from about 0.2 cm³/g to about 0.6 cm³/g, from about 0.2 cm³/g to about 0.5 cm³/g, from about 0.3 cm³/g to about 1 cm³/g, from about 0.3 cm³/g to about 0.9 cm³/g, from about 0.3 cm³/g to about 0.8 cm³/g, from about 0.3 cm³/g to about 0.7 cm³/g, from about 0.3 cm³/g to about 0.6 cm³/g, or from about 0.3 cm³/g to about 0.5 cm³/g. Carbon black materials with these specific pore volumes provide a volume sufficient to provide uniform wetting and good dispersion of the catalytically active components while enabling sufficient contact between the reactant molecules and the catalytically active surface. Mean pore diameters and pore volumes are determined in accordance with the procedures described in E. P. Barrett, L. G. Joyner, P. P. Halenda, J. Am. Chem. Soc. 1951, 73, 373-380 (BJH method), and ASTM D4222-03(2008) Standard Test Method for Determination of Nitrogen Adsorption and Desorption Isotherms of Catalysts and Catalyst Carriers by Static Volumetric Measurements, which are incorporated herein by reference.

Specific examples of commercially available carbon black and carbon black-containing materials that are suitable for use in the present invention include those listed in the following table. The specific surface area, specific pore volume, and mean pore diameter listed below were measured by applicant using the methods described herein.

N₂ BET N₂ BJH N₂ BJH Specific Specific Mean Surface Pore Pore Carbon Material Area Volume Diameter Carbon Material Manufacturer (m²/g) (cm³/g) (nm) Asbury 5991 Asbury 7 0.01 9.7 THERMAX Cancarb 7 0.01 16.1 FloForm N990 THERMAX Cancarb 8 0.01 9.4 Powder Ultra Pure N991 THERMAX Ultra Cancarb 8 0.02 17.7 Pure N990 THERMAX Cancarb 8 0.01 8.7 Powder N991 AROSPERSE 15 Orion 8 0.02 10.4 Lamp Black 101 Orion 20 0.03 8.0 MONARCH 120 Cabot 23 0.07 27.7 MONARCH 280 Cabot 30 0.08 17.6 N762 Continental Carbon 31 0.10 13.9 Asbury 5345 Asbury 37 0.10 10.7 N550 Continental Carbon 38 0.10 11.7 MONARCH 280 Cabot 38 0.08 9.7 N120 Continental Carbon 39 0.09 10.0 AROSPERSE Orion 39 0.09 9.3 5-183A ENSACO 150G Imerys Graphite & 46 0.10 9.7 Carbon - TIMCAL ENSACO 150G Imerys Graphite & 47 0.17 13.6 Carbon - TIMCAL SC119 Sid Richardson 51 0.14 12.2 ENSACO 250G Imerys Graphite & 56 0.17 16.5 Carbon - TIMCAL ENSACO 250P Imerys Graphite & 56 0.13 9.3 Carbon - TIMCAL ENSACO 260G Imerys Graphite & 63 0.18 10.4 Carbon - TIMCAL ENSACO 250G Imerys Graphite & 64 0.24 14.0 Carbon - TIMCAL ENSACO 250P Imerys Graphite & 67 0.13 9.6 Carbon - TIMCAL SR311 Sid Richardson 74 0.23 12.6 N330 Continental Carbon 77 0.33 17.0 MONARCH 570 Cabot 102 0.30 13.8 AROSPERSE 138 Orion 112 0.45 18.7 N234 Continental Carbon 117 0.39 13.6 N115 Sid Richardson 128 0.49 16.7 (ground) SC419 Sid Richardson 136 0.56 16.8 SR155 Sid Richardson 146 0.87 22.2 HP160 Orion 158 0.87 20.8 CONDUCTEX K Columbian 167 0.31 10.6 Ultra Chemicals (Aditya Birla) CONDUCTEX SC Columbian 169 0.33 11.3 Ultra Beads Chemicals (Aditya Birla) MONARCH 700 Cabot 181 0.38 12.1 HIBLACK 50LB Orion 183 0.61 15.4 RAVEN 2000 Columbian 187 0.68 14.6 Beads Chemicals (Aditya Birla) HIBLACK 50 L Orion 193 0.66 15.7 HP-160 Degussa 200 MONARCH 700 Cabot 206 0.38 10.5 HIBLACK 600 L Orion 208 0.76 15.2 Asbury 5302 Asbury 211 0.29 9.9 VULCAN XC72R Cabot 217 0.24 7.5 VULCAN XC72R Cabot 218 0.24 8.1 Asbury 5303 Asbury 219 0.23 7.9 SC159 Sid Richardson 222 0.48 11.5 20.4 kg (45 lb) bag VULCAN XC72 Cabot 230 0.32 9.4 VULCAN XC72R Cabot 231 0.28 7.1 VULCAN XC72 Cabot 231 0.30 8.3 SC159 Sid Richardson 231 0.52 12.8 SC159 Sid Richardson 234 0.81 18.2 VULCAN XC72 Cabot 237 0.34 8.2 PRINTEX L6 Orion 242 0.33 11.4 RAVEN 2500 Ultra Columbian 247 0.67 12.2 Beads Chemicals (Aditya Birla) Asbury 5379 Asbury 271 0.83 16.3 Asbury 5368 Asbury 303 0.54 10.2 RAVEN 3500 Columbian 320 0.87 14.5 Beads Chemicals (Aditya Birla) COLOUR BLACK Orion 390 0.91 15.6 FW 2 COLOUR BLACK Orion 479 0.83 12.2 FW 200 RAVEN 5000 Ultra Columbian 508 0.65 7.3 II Beads Chemicals (Aditya Birla) RAVEN 5000 Ultra Columbian 539 0.57 6.2 3 Beads Chemicals (Aditya Birla) COLOUR BLACK Orion 546 1.10 11.9 FW 255 COLOUR BLACK Orion 567 1.13 12.0 FW 171 RAVEN 7000 Columbian 577 0.94 10.7 Beads Chemicals (Aditya Birla) ENSACO 350G Imerys Graphite & 739 0.74 5.8 Carbon - TIMCAL PRINTEX XE-2B Orion 1060 1.41 5.9

Certain carbon black materials are known to be electrically conductive. Accordingly, in various embodiments, the shaped porous carbon product comprises conductive carbon black and in some embodiments, the shaped porous carbon product is electrically conductive. In other embodiments, the shaped porous carbon product comprises nonconductive carbon black. In further embodiments, the shaped porous carbon product comprises nonconductive carbon black wherein the shaped porous carbon product does not exhibit a conductivity that is suitable for a conductive electrode. In certain embodiments, the shaped porous carbon product comprises nonconductive carbon black and less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, less than about 5%, or less than about 1% conductive carbon black based on the total weight of the carbon black in the shaped porous carbon product and/or the total weight of the carbon black used to prepare the shaped porous carbon product. In some embodiments, the shaped porous carbon product comprises carbon black consisting of or consisting essentially of nonconductive carbon black. In some embodiments, the carbon black comprises a silica-bound or alumina-bound carbon black. In certain embodiments, the shaped porous carbon product can further include graphite and/or a metal oxide (e.g., alumina, silica, titania, and the like).

The shaped porous carbon product comprising the carbonaceous material (e.g., carbon black) may be prepared by various methods such as dry powder pressing, drip casting, injection molding, 3D-printing, extrusion and other pelletizing and granulating methods. For example, dry powder pressing involves compressing the carbonaceous material (e.g., carbon black particles) in a press such as a hot or cold isostatic press or a calandering press. Other pelletizing and granulating methods include tumbling the carbonaceous material and contacting the particles with a spray containing a binder.

Methods of preparing the shaped porous carbon product generally comprise mixing a carbonaceous material and a binder to form a carbon-binder mixture; forming the carbon-binder mixture to produce a shaped carbon composite; heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product. In various embodiments, methods of preparing the shaped porous carbon product comprise mixing a solvent such as water, a carbonaceous material, and a binder to form a carbon-binder mixture; forming the carbon-binder mixture to produce a shaped carbon composite; heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

In some embodiments, methods of preparing the shaped porous carbon product comprise mixing water, carbon black, and a binder to form a carbon black mixture; forming the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product. In various methods of preparing the shaped porous carbon products, a binder solution can be prepared by mixing water and the binder prior to mixing with carbon black.

The water content of the carbon-binder mixture (e.g., carbon black mixture) is typically no more than about 80% by weight, no more than about 55% by weight, no more than about 40% by weight, or no more than about 25% by weight. In various embodiments, the water content of the carbon-binder mixture (e.g., carbon black mixture) can be from about 5 wt. % to about 70 wt. %, from about 5 wt. % to about 55 wt. %, from about 5 wt. % to about 40 wt. %, or from about 5 wt. % to about 25 wt. %.

The viscosity of the binder solution can vary, for example, according to the binder content and can be readily adjusted to suit a particular shaping process by varying the relative quantities of solid and liquid components. For example, the viscosity of the aqueous solution can be varied by adjusting the amount of binder and type of binder utilized (binder types may differ with respect to, for example, saccharide type, polymer class, molecular weight, average molecular weight of polymer, molecular weight polydispersity of polymer, etc.). Also in various methods, the water and binder can be mixed and heated to form the binder solution. In some instances, heating can enhance the amount of binder that can be incorporated into the binder solution and/or carbon-binder mixture (e.g., carbon black mixture) by increasing the solubility of the binder. For example, the water and binder can be heated to a temperature of at least about 50° C., at least about 60° C., or at least about 70° C. In various embodiments, the water and binder can be heated to a temperature of from about 50° C. to about 95° C., from about 50° C. to about 90° C., or from about 60° C. to about 85° C.

After mixing and heating to form the binder solution, the binder solution can be cooled as needed prior to mixing with the carbonaceous material (e.g., carbon black) or prior to forming the shaped carbon composite.

One method of preparing the shaped porous carbon product of the present invention comprises mixing carbon black particles with a solution comprising a binder to produce a slurry; forming the slurry (e.g., by extrusion) to produce a shaped carbon black composite and heating or pyrolyzing the shaped carbon black composite to carbonize the binder to produce the shaped porous carbon product.

In various methods of preparing the shaped porous carbon product, a binder solution or binder and water are thoroughly mixed and blended with the carbonaceous material (e.g., carbon black) to prepare a carbon-binder mixture (e.g., a slurry or a paste). The weight ratio of binder to carbonaceous material in the carbon-binder mixture (e.g., carbon black in the carbon black mixture) is typically at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1, or at least 1.5:1. In some embodiments, the weight ratio of binder to carbonaceous material in the carbon-binder mixture (e.g., carbon black in the carbon black mixture) is no more than about 1:4, no more than about 1:5, or no more than about 1:10. The weight ratio of binder to carbonaceous material in the carbon-binder mixture (e.g., carbon black in the carbon black mixture) can also be from about 1:10 to about 3:1, from about 1:10 to about 1:1, from about 1:10 to about 1:4, from about 1:4 to about 3:1, from about 1:4 to about 1:1, from about 1:3 to about 2:1, from about 1:3 to about 1:1, or about 1:1.

Typically, the carbonaceous material in the carbon-binder mixture (e.g., carbon black in the carbon black mixture) is at least about 35 wt. % or more such as at least about 40 wt. %, at least about 45 wt. %, as at least about 50 wt. %, as at least about 55 wt. %, at least about 60 wt. %, at least about 65 wt. %, at least about 70 wt. %, at least about 75 wt. %, at least about 80 wt. %, at least about 85 wt. %, or at least about 90 wt. % on a dry weight basis. In various embodiments, the carbonaceous material in the carbon-binder mixture (e.g., carbon black in the carbon black mixture) is from about 35 wt. % to about 90 wt. %, from about 35 wt. % to about 80 wt. %, from about 35 wt. % to about 75 wt. %, from about 40 wt. % to about 90 wt. %, from about 40 wt. % to about 80 wt. %, from about 40 wt. % to about 75 wt. %, from about 35 wt. % to about 50 wt. %, from about 38 wt. % to about 48 wt. %, or from about 45 wt. % to about 50 wt. % on a dry weight basis. Also, the binder content of the carbon-binder mixture (e.g., carbon black mixture) is typically at least about 5 wt. %, at least about 10 wt. %, at least about 20 wt. %, at least about 25 wt. %, at least about 30 wt. %, at least about 35 wt. %, at least about 40 wt. %, at least about 45 wt. %, at least about 50 wt. %, at least about 55 wt. %, at least about 60 wt. %, or at least about 65 wt. % on a dry weight basis. In various methods for preparing the shaped porous carbon product of the present invention as described herein, the binder content of the carbon-binder mixture (e.g., carbon black mixture) is from about 5 wt. % to about 65 wt. %, from about 5 wt. % to about 50 wt. %, from about 5 wt. % to about 45 wt. %, from about 10 wt. % to about 65 wt. %, from about 10 wt. % to about 50 wt. %, from about 10 wt. % to about 45 wt. %, from about 15 wt. % to about 50 wt. %, from about 20 wt. % to about 65 wt. %, from about 20 wt. % to about 50 wt. %, from about 20 wt. % to about 45 wt. %, from about 30 wt. % to about 65 wt. %, from about 30 wt. % to about 60 wt. %, from about 35 wt. % to about 65 wt. %, from about 40 wt. % to about 65 wt. %, from about 50 wt. % to about 65 wt. %, or from about 50 wt. % to about 65 wt. % on a dry weight basis.

Various methods of preparing the shaped porous carbon products can further comprise pressing or kneading the carbon-binder mixture (e.g., carbon black mixture). Pressing or kneading the carbon-binder mixture compacts the mixture and can reduce the water content of the mixture. Pressing or kneading of the water, carbonaceous material, and binder (e.g., carbon black mixture) can be conducted simultaneously with the mixing of the water, carbonaceous material and binder. For example, one method of mixing the water, carbonaceous material, and binder and simultaneously pressing the resulting carbon-binder mixture can be conducted using a mixer muller.

After mixing of the carbonaceous material and binder, the resulting carbon-binder mixture is formed into a shaped carbon composite structure of the desired shape and dimensions by a forming technique such as extrusion, pelletizing, pilling, tableting, cold or hot isostatic pressing, calandering, injection molding, 3D printing, drip casting, or other methods known to produce shaped structures. Forming methods such as cold or hot isostatic pressing and 3D printing may or may not require a binder.

In general, the shaped porous carbon product can be shaped and sized for use in known industrial reactor formats such as batch slurry, continuous slurry-based stirred tank reactors, fixed beds, ebulated beds and other known industrial reactor formats. The shaped porous carbon product may be formed into various shapes including spheres, beads, cylinders, pellets, multi-lobed shapes, rings, stars, ripped cylinders, triholes, alphas, wheels, etc. Also, the shaped porous carbon product may be formed into amorphous, non-geometric, and random shapes as well as unsymmetrical shapes like hi-flow rings and cones and alpha-rings. The mean diameter of the shaped porous carbon product is typically at least about 50 μm (0.05 mm), at least about 500 μm (0.5 mm), at least about 1,000 μm (1 mm), at least about 10,000 μm (10 mm) or larger to accommodate process requirements.

For extrusion forming, a pressure of at least about 100 kPa (1 bar), at least about 1,000 kPa (10 bar), at least about 3,000 kPa (30 bar), at least about 4,000 kPa (40 bar) or between about 100 kPa (1 bar) to about 10,000 kPa (100 bar), between about 1,000 kPa (10 bar) to about 5,000 kPa (50 bar), between 500 kPa (5 bar) and 5,000 kPa (50 bar), or between 1,000 kPa (10 bar) and 3,000 kPa (30 bar) is typically applied to the carbon-binder mixture (e.g., carbon black mixture).

In drip casting methods, the carbon-binder mixture (e.g., carbon black mixture comprising carbon black particles and the binder) are dispensed as droplets into a casting bath to form the shaped carbon composite, which is then separated from the casting bath. Carbon-binder mixture droplets of a tailored diameter may be dispensed through a sized nozzle and dropped into a bath to produce solidified, spherically-shaped carbon composites of various diameters. In various embodiments of this method, the binder comprises an alginate (or alginate in combination with another carbohydrate binder as described herein) which can be dispensed into a bath containing a reagent to cause solidification such as an ionic salt (e.g., calcium salt) as described in U.S. Pat. No. 5,472,648, the entire contents of which are incorporated herein by reference. The droplets are subsequently allowed to remain substantially free in the ionic solution until the required degree of solidification and consolidation has been attained. Alternatively, the drip casting bath utilized may be, for example, an oil bath, or a bath to cause freeze drying. When an oil bath is used, the temperature of the oil is sufficiently high that the binder is thermally set (e.g., causes the binder to convert to a three-dimensional gel). When a freeze drying bath is used, the resultant beads are typically dried by vacuum treatment. The shaped carbon composites resulting from such dip casting methods are subsequently pyrolyzed.

As described in further detail below, other components can be added to the carbon-binder mixture (e.g., carbon black mixture) to assist with the shaping process (e.g., lubricants, compatibilizers, etc.) or to provide other benefits. In various embodiments, the carbon-binder mixture further comprises a forming adjuvant. For example, the forming adjuvant can comprise a lubricant. Suitable forming adjuvants include, for instance, lignin or lignin derivatives.

Further, porogens may be mixed with the carbonaceous material and binder to modify and attain the desired pore characteristics in the shaped porous carbon product. Other methods of modifying the porosity of the shaped porous carbon product include mixing two or more different carbonaceous starting materials (e.g., carbon blacks having different shape and/or size that pack irregularly resulting in multimodal pore size distributions, or carbon blacks from different sources/suppliers, or mixing carbon black powders carbon). Other methods of modifying the porosity of the shaped porous carbon product include multiple thermal processing and/or multiple compounding (e.g., pyrolysis of a shaped carbon black composite of carbon powder and binder, then mixing with fresh carbon black powder and binder and pyrolyzing the resultant composite again).

In various methods of preparing the shaped porous carbon product, after processing the carbon-binder mixture (e.g., a slurry or a paste) into the shaped carbon composite, the composite may be dried to remove at least a portion of the solvent contained therein (e.g., to dehydrate the composite). Drying may be achieved by heating the composite at atmospheric pressure and temperatures typically of from about room temperature (e.g., about 20° C.) to about 150° C., from about 40° C. to about 120° C., or from about 60° C. to about 120° C. Other methods of drying may be utilized including vacuum drying, freeze drying, and desiccation. When using certain preparation methods for forming (e.g., tableting, pressing), no drying step may be required.

In certain instances, it has been found that the drying conditions of the shaped carbon composite can affect the mechanical strength of the shaped porous carbon product. In particular, it has been found that when the shaped carbon composite is dried relatively fast at higher temperatures (e.g., greater than about 90° C.), then the resulting shaped porous carbon product (following carbonization of the binder) has a mechanical strength that is further improved when compared to a product prepared under relatively slow drying conditions. Without being bound by theory, applicants propose that relatively fast drying conditions may prevent or reduce migration of the binder components to the surface of the carbonaceous material. It is believed that preventing or reducing this migration of the binder components may contribute to even further enhancement to mechanical strength of the shaped porous carbon product, as compared to a product prepared under relatively slow drying conditions at lower temperatures (e.g., less than 90° C.).

Accordingly, various processes of the present invention for preparing a shaped porous carbon product can comprise drying the shaped carbon composite quickly at elevated temperatures. In these embodiments, processes for preparing a shaped porous carbon product can comprise drying the shaped carbon composite at a temperature from about 90° C. to about 175° C., from about 90° C. to about 150° C., from about 100° C. to about 150° C., or from about 100° C. to about 140° C. Drying at an elevated temperature within these ranges advantageously reduces the time necessary to achieve a sufficiently dried shaped carbon composite.

Typically, the water content of the shaped carbon composite after drying is no greater than about 25 wt. %, no greater than about 20 wt. %, no greater than about 15 wt. %, no greater than about 12 wt. %, no greater than about 11 wt. %, or no greater than about 10 wt. %. For example, the water content of the shaped carbon composite after drying can be from about 2 wt. % to about 25 wt. %, from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 15 wt. %, from about 2 wt. % to about 12 wt. %, from about 2 wt. % to about 11 wt. %, from about 2 wt. % to about 10 wt. %, from about 4 wt. % to about 15 wt. %, from about 4 wt. % to about 12 wt. %, from about 4 wt. % to about 11 wt. %, from about 4 wt. % to about 10 wt. %, from about 5 wt. % to about 15 wt. %, from about 5 wt. % to about 12 wt. %, from about 5 wt. % to about 11 wt. %, or from about 5 wt. % to about 10 wt. %. Also, in various embodiments, drying can be conducted over a period of time that is no more than about 120 minutes, no more than about 90 minutes, no more than about 75 minutes, no more than about 60 minutes, no more than about 45 minutes, no more than about 30 minutes, or no more than about 20 minutes. For instance, drying can be conducted over a period of time that is from about 30 minutes to about 120 minutes, from about 30 minutes to about 90 minutes, from about 30 minutes to about 75 minutes, from about 30 minutes to about 60 minutes, from about 30 minutes to about 45 minutes, from about 60 minutes to about 120 minutes, from about 60 minutes to about 90 minutes, from about 20 minutes to about 60 minutes, or from about 20 minutes to about 45 minutes.

In some processes of preparing the shaped porous carbon product, it has been found that the time elapsed between drying and the carbonization step can affect the mechanical strength of the shaped porous carbon product. In some instances, when the shaped carbon composite is stored for a significant amount of time before carbonization, then the mechanical strength of the shaped porous carbon product is lower as compared to a shaped carbon composite that is immediately or almost immediately introduced to the carbonization step. Applicants have unexpectedly found that drying the shaped carbon composite to a water content of about 11 wt. % or less provides for a shaped porous carbon product that has enhanced mechanical strength (e.g., a radial piece crush strength that is greater than about 8.8 N/mm (2 lbs/mm)) even if the shaped carbon composite is not immediately carbonized following drying.

Drying can be conducted using a technique that can effect rapid drying. For example, drying can be performed using a continuous belt dryer. In belt drying, temperatures and residence time can be adjusted to provide a dried shaped carbon composite having the reduced water contents specified herein.

Following forming and drying, the shaped carbon composite is heated in a heating zone to carbonize the binder (e.g., pyrolyze) thereby producing the shaped porous carbon product. In various methods of preparing the shaped porous carbon product, the shaped carbon composite (e.g., resulting from extrusion, pelletizing, pilling, tableting, cold or hot isostatic pressing, calandering, injection molding, 3D printing, drip casting, and other forming methods) is heated in an inert (e.g., an inert nitrogen atmosphere), oxidative, or reductive atmosphere to carbonize at least a portion of the binder to a water insoluble state and produce a shaped porous carbon product. Preferably, heating is conducted in an inert atmosphere.

Generally, the shaped carbon composite is heated to a final temperature of at least about 400° C., at least about 500° C., at least about 600° C., at least about 700° C., or at least about 800° C. in the heating zone. Heating can be conducted at a temperature of from about 250° C. to about 1,000° C., from about 300° C. to about 900° C., from about 300° C. to about 850° C., from about 300° C. to about 800° C., from about 350° C. to about 850° C., from about 350° C. to about 800° C., from about 350° C. to about 700° C., from about 400° C. to about 850° C. or from about 400° C. to about 800° C. In various embodiments, the shaped carbon composite is heated to a final temperature of from about 400° C. to about 1,000° C., from about 400° C. to about 900° C., from about 400° C. to about 850° C., from about 400° C. to about 800° C., from about 500° C. to about 850° C., from about 500° C. to about 800° C., from about 500° C. to about 700° C., from about 600° C. to about 850° C. or from about 600° C. to about 800° C. in the heating zone.

The heating zone can include a single or multiple heating stages. In various embodiments, the heating zone comprises at least two heating stages that are each maintained at an approximately constant temperature (e.g., ±5-10° C.) and the temperature of each stage differs by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. with the temperature increasing from one stage to the next. In some embodiments, the heating zone comprises at least three, at least four, at least five, or at least six heating stages that are each maintained at an approximately constant temperature and the temperature of each stage independently differs by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. from the preceding stage. In various embodiments, the temperature of each stage differs by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

In certain embodiments the heating zone comprises: (1) a first heating stage where the shaped carbon composite is heated at a first temperature; and (2) a second heating stage where the shaped carbon composite is heated at a second temperature. In these embodiments, the first and second temperature are each approximately constant and the second temperature is greater than the first temperature by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. For example, the temperature of the first heating stage temperature and the second stage heating stage can differ by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

In further embodiments, the heating zone comprises a third heating stage where the shaped carbon composite is heated at a third temperature that is approximately constant and is greater than the second heating stage temperature by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. For example, the temperature of the second heating stage temperature and the third stage heating stage temperature can differ by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

When a continuous process for producing the shaped porous carbon product is desired, then the heating zone can be within a continuous rotary kiln or belt conveyor furnace. As noted, various embodiments include the use of a heating zone comprising multiple heating stages. Thus, in these instances, a multi-stage continuous rotary kiln or belt conveyor furnace can be used to heat the shaped carbon composite.

The heating zone can further include one or more stages for drying the shaped carbon composite prior to carbonization. In other words, the drying step and carbonization step can be conducted in a heating zone comprising a series of heating stages (multi-stage heating zone) in which at least the first heating stage (e.g., one, two, or three heating stages for drying) is at a temperature suitable for drying, such as in the range of from about 90° C. to about 175° C., from about 90° C. to about 150° C., from about 100° C. to about 150° C., or from about 100° C. to about 140° C. Carbonization of at least a portion of the binder to produce the shaped porous carbon product can be completed in higher temperature heating stages that are subsequent to those for drying. These higher temperature stages can be operated as previously discussed. A belt conveyor furnace is one type of furnace suitable for a multi-stage heating zone that can be adapted to include one or more stages for drying and one or more higher temperature stages for carbonization of the binder.

In some instances and depending upon the binder employed, it has been determined that lower carbonization temperatures can lead to slow leaching of the remnants of the binder from the shaped porous carbon product which reduces mechanical strength over extended periods of use in catalytic reactions. Generally, to ensure longer term stability, the heat treatment is conducted at higher carbonization temperatures within the ranges specified above. In some instances, the resultant shaped porous carbon product may be washed after the heat treatment to remove impurities.

In accordance with various preparation methods, shaped porous carbon products of the present invention comprise a binder or carbonization product thereof in addition to the carbonaceous material (e.g., carbon black). Various references, including U.S. Pat. No. 3,978,000, describe the use of acetone soluble organic polymers and thermosetting resin as binders for shaped carbon supports. However, the use of flammable organic solvents and expensive thermosetting resins is not desirable or economical for manufacturing large quantities of shaped porous carbon product.

Mechanically-strong, shaped porous carbon products of the invention can be prepared by the use of an effective binder. The use of an effective binder provides a robust shaped porous carbon product capable of withstanding the prevailing conditions within continuous liquid phase flow environments such as in conversions of biorenewably-derived molecules or intermediates in which the liquid phase may contain water or acidic media. In such instances the shaped porous carbon product is mechanically and chemically stable to enable long-term operation without significant loss in catalyst performance. Moreover, the use of an effective binder provides a robust shaped porous carbon product capable of withstanding elevated temperatures.

Applicants have found that readily available water soluble organic compounds are suitable binders for the preparation of mechanically strong shaped porous carbon products. As used in herein, a binder is deemed water soluble if the solubility at 50° C. is at least about 1 wt. %, preferably at least about 2 wt. %. Aqueous solutions of organic binders are highly amenable to commercial manufacturing methods. Organic binders that dissolve in aqueous solutions enable good mixing and dispersion when contacted with the carbonaceous materials (e.g., carbon black). These binders also avoid safety and processing issues associated with large-scale use of organic solvents which may be flammable and require special storage and handling. Also, these binders are relatively inexpensive when compared to costly polymer-based binders. As such, in various embodiments, the carbon-binder mixtures (e.g., carbon black mixtures) do not contain water immiscible solvents.

However, in some embodiments, a solvent in addition to or in place of water can be used. For example, water-miscible solvents such as ethylene glycol, glycerol, lactic acid, and mixtures thereof can replace in its entirety or at least a portion of the water. In certain embodiments, the solvent is free or substantially free of water (e.g., the water content of the carbon-binder mixture is typically no more than about 5% by weight, no more than about 2% by weight, no more than about 1% by weight, or no more than about 0.1% by weight. In other embodiments, the carbon-binder mixture is prepared without a solvent (e.g., the carbon-binder mixture is solvent-free or substantially free of solvent).

Generally, water soluble organic binders can include carbohydrates or derivatives thereof, which may be a monomeric or oligomeric or polymeric carbohydrate (also known as saccharides, oligosaccharide and polysaccharides). Derivatives of carbohydrates (in monomeric or oligomeric polymeric forms) are also included wherein a functional group or groups bound to the carbohydrate may be exchanged or derivatized. Such derivatives may be acidic or charged carbohydrates such as alginic acid or alginate salts, or pectin, or aldonic acids, aldaric acids, uronic acids, xylonic or xylaric acids (or oligomers, or polymers or salts thereof). Other derivatives include sugar alcohols and polymeric forms thereof (e.g., sorbitol, mannitol, xylitol or polyols derived from carbohydrates). The carbohydrate binder may be used in the form of syrups such as molasses or corn syrups or soluble starches or soluble gum or modified versions thereof.

In various embodiments, the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer. In some embodiments, the water soluble organic binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof. For example, in certain embodiments, the water soluble organic binder comprises a monosaccharide. The monosaccharide can be selected from the group consisting of glucose, fructose, hydrates thereof, syrups thereof (e.g., corn syrups, molasses, and the like) and combinations thereof. One preferred monosaccharide is glucose. In further embodiments, the water soluble organic binder comprises a disaccharide. Disaccharides include for example, maltose, sucrose, syrups thereof, and combinations thereof. Saccharides that have been peptized can also be used.

The binder can comprise a water soluble polymer. In various instances, it has been found that water soluble polymers capable of yielding relatively low viscosities solutions and/or low molecular weight (i.e., number average molecular weight) provide a shaped porous carbon product having enhanced mechanical strength. Accordingly, in various embodiments, the binder comprises a water soluble polymer, wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity of no greater than about 500 mPa·s, no greater than about 400 mPa·s, no greater than about 300 mPa·s, no greater than about 200 mPa·s, no greater than about 100 mPa·s, no greater than about 75 mPa·s, or no greater than about 50 mPa·s at 25° C. and/or the water soluble polymer has a number average molecular weight (M_(n)) that is no greater than about 50,000 g/mol, no greater than about 40,000 g/mol, no greater than about 30,000 g/mol, no greater than about 25,000 g/mol, or no greater than about 20,000 g/mol. In some embodiments, the binder comprises a water soluble polymer, wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity that is from about 2 to about 500 mPa·s, from about 2 to about 400 mPa·s, from about 2 to about 300 mPa·s, from about 2 to about 200 mPa·s, from about 2 to about 150 mPa·s, from about 2 to about 100 mPa·s, from about 2 to about 75 mPa·s, or from about 2 to about 50 mPa·s at 25° C. In these and other embodiments, the water soluble polymer can have a number average molecular weight (M_(n)) that is from about 2,000 to about 50,000 g/mol, from about 5,000 to about 40,000 g/mol, from about 5,000 to about 30,000 g/mol, from about 5,000 to about 25,000 g/mol, from about 5,000 to about 20,000 g/mol, from about 10,000 to about 50,000 g/mol, from about 10,000 to about 40,000 g/mol, from about 10,000 to about 30,000 g/mol, from about 10,000 to about 25,000 g/mol, or from about 10,000 to about 20,000 g/mol.

In some instances, it has been discovered that a relatively small amount of the water soluble polymer provides enhanced mechanical strength to the shaped porous carbon product. Accordingly, in various embodiments, the water soluble polymer can constitute no more than about 5 wt. %, no more than about 4 wt. %, no more than about 3 wt. %, or no more than about 2 wt. % based on the weight of the water, saccharide, and water soluble polymer mixed with the carbonaceous material. In some embodiments, the water soluble polymer can constitute from about 0.5 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, from about 0.5 wt. % to about 3 wt. %, from about 0.5 wt. % to about 2 wt. %, from about 1 wt. % to about 5 wt. %, from about 1 wt. % to about 4 wt. %, from about 1 wt. % to about 3 wt. %, or from about 1 wt. % to about 2 wt. % based on the weight of the water, and saccharide, and water soluble polymer mixed with the carbonaceous material.

Suitable water soluble polymers include various polymeric carbohydrates, derivatives of polymeric carbohydrates, non-carbohydrate synthetic polymers, or any combination thereof. For example, polymeric carbohydrates or derivatives of the polymeric carbohydrates can comprise cellulosic compounds. Cellulosic compounds include, for example, methylcellulose, ethylcellulose, ethylmethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, methylhydroxyethylcellulose, ethylhydroxyethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, and mixtures thereof. One preferred cellulosic compound is hydroxyethylcellulose.

Further, the polymeric carbohydrate or derivative of the polymeric carbohydrate derivative can be selected from the group consisting of alginic acid, pectin, aldonic acids, aldaric acids, uronic acids, sugar alcohols, and salts, oligomers, and polymers thereof. The polymeric carbohydrate or derivative of the polymeric carbohydrate can also comprise a starch or a soluble gum.

In various embodiments, the binder comprises a non-carbohydrate synthetic polymer. Water soluble polymers or copolymers may be used as binders. For example, polyacrylic acid, polyvinyl alcohols, polyvinylpyrrolidones, polyvinyl acetates, polyacrylates, polyethers (such as, for example, polyethyelene glycol and the like) and copolymers (which can be block copolymers comprising a water insoluble block monomers and water soluble block monomers) derived therefrom, and blends thereof. In some instances, the water soluble copolymer may be a block copolymer comprising a water soluble polymer block and a second polymer block which may be hydrophobic and amenable to carbonization (e.g., polystyrene). In another embodiment, polymer dispersions in water are used as binders, i.e., non-water soluble polymers dispersed in water (with the aid of surfactants) such as commercial polyvinyl alcohol, polyacrylonitrile, polyacrylonitrile-butadiene-styrene, phenolic polymer or lignin polymer dispersions. Also copolymers consisting of a water-soluble branch (e.g., polyacrylic acid) and a hydrophobic branch (e.g., polymaleic anhydride, polystyrene) enabling water solubility of the copolymer and enabling carbonization of the hydrophobic branch without depolymerisation upon pyrolysis. Carbohydrates or derivatives thereof, water soluble polymers and polymer dispersions in water may be used together in various combinations.

Binders comprising a combination of a saccharide and water soluble polymer have been found to provide shaped porous carbon products exhibiting enhanced mechanical strength. Accordingly, in various embodiments, the water soluble organic binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a water soluble polymer (e.g., a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof). The weight ratio of (i) the saccharide to (ii) water soluble polymer (e.g., the polymeric carbohydrate, derivative of the polymeric carbohydrate, or the non-carbohydrate synthetic polymer, or combination thereof) can be from about 5:1 to about 100:1, from about 5:1 to about 50:1, 10:1 to about 40:1, from about 10:1 to about 30:1, from about 10:1 to about 25:1, from about 10:1 to about 20:1, from about 20:1 to about 30:1, or from about 25:1 to about 30:1.

As described above, water soluble organic binders that may be used in combination with the saccharide binders include water soluble celluloses and starches (e.g., hydroxyethylcellulose, hydroxypropylcellulose, hydroxyethylmethylcellulose, hydroxylpropylmethylcellulose, carboxymethylcellulose), water soluble alcohols (e.g., sorbitol, xylitol, polyvinyl alcohols), water soluble acetals (e.g., polyvinylbutyral), water soluble acids (e.g., stearic acid, citric acid, alginic acid, aldonic acids, aldaric acids, uronic acids, xylonic or xylaric acids (or oligomers, or polymers or salts or esters thereof) polyvinyl acrylic acids (or salts or esters thereof). In some embodiments, the combination of water soluble organic binders comprises a cellulosic compound and a monosaccharide. In certain embodiments, the cellulosic compound comprises hydroxyethylcellulose, or methylcellulose and the monosaccharide comprises a glucose, fructose or hydrate thereof (e.g., glucose). In particular, one combination comprises glucose and hydroxyethylcellulose, which provides shaped porous carbon products with enhanced mechanical strength, particularly when processed at high carbonization temperatures. In other embodiments the combination of water soluble organic binders comprises a monosaccharide and a water-soluble alcohol such as sorbitol, mannitol, xylitol or a polyvinyl alcohol. In other embodiments, the combination of water soluble organic binders comprises a monosaccharide, and a water-soluble acid such as stearic acid, pectin, alginic acid or polyacrylic acid (or salts thereof). In further embodiments, the combination of water soluble organic binders comprises a monosaccharide and a water-soluble ester such as a polyacrylate or polyacetate. In still other embodiments, the combination of water soluble organic binders comprises a monosaccharide and a water-soluble acetal such as a polyacetal (e.g., polyvinylbutyral).

Other water soluble compounds may be used in combination with a carbohydrate or polymeric binder. Combining a carbohydrate or other binder with selected other water soluble organic compounds can provide advantages in the preparation of and in the properties of the resultant shaped porous carbon product. For example, water soluble organic compounds such as stearic acid or stearates such as Zr or NH₄ stearate can provide lubrication during the forming process. Wetting agents may be added (e.g., GLYDOL series available commercially from Zschimmer and Schwarz).

Porogens may also be added in combination with the binder (or binders). Porogens are typically added to occupy a specific molecular volume within the formulation such that after the shaping and thermal processing the porogen will be pyrolyzed leaving pores of a certain volume and diameter within the shaped product. The presence of such pores can be beneficial to performance. For example, when used as a catalyst support the presence of such pores can lead to more efficient diffusion (of reactants and products) to and from the catalytically active surfaces. More efficient access and egress for the reactants and products can lead to improvements in catalyst productivity and selectivity. Porogens are typically oligomeric (e.g., dimer, trimers of higher order oligomers) or polymeric in nature. Water soluble organic compounds such as water soluble linear and branched polymers and cross-linked polymers are suitable for use as porogens. Polyacrylates (such as weakly cross-linked polyacrylates known as superabsorbers), polyvinyl alcohols, polyvinylacetates, polyesters, polyethers, or copolymers (which may be block copolymers) thereof may be used as porogens. In some instances, the water soluble copolymer may be a block copolymer comprising a water soluble polymer block and a second polymer block which may be hydrophobic and amenable to carbonization (e.g., polystyrene). In another embodiment, polymer dispersions in water are used as binders, i.e., non-water soluble polymers dispersed in water (with the aid of surfactants) such as commercial polyvinyl alcohol, polyacrylonitrile, polyacrylonitrile-butadiene-styrene, phenolic polymer dispersions. Also copolymers consisting of a water-soluble branch (e.g., polyacrylic acid) and a hydrophobic branch (e.g., polymaleic anhydride, polystyrene) enabling water solubility of the copolymer and enabling carbonization of the hydrophobic branch without depolymerisation upon pyrolysis. Carbohydrates or derivatives thereof, (disaccharides, oligosaccharides, polysaccharides such as sucrose, maltose, trihalose, starch, cellubiose, celluloses), water soluble polymers and polymer dispersions in water may be used together in any combination as a porogen to attain a shaped porous carbon product having the desired pore size and volume characteristics described herein.

Porogens can also be added as gels (e.g., pre-gelated superabsorber) or water insoluble incompressible solids (e.g., polystyrene microbeads, lignins, phenolic polymers) or expandable porogens such as EXPANSEL microspheres available from Akzo Nobel Pulp and Performance (Sundsvall, Sweden). The molecular weight of the oligomer or polymer can be also chosen to design a desired pore sizes and volume characteristics of the shaped carbon product of the invention. For example the desired shaped carbon product may have a monomodal, bimodal or multimodal pore size distribution as a consequence of addition of a porogen. For illustration, a bimodal or multimodal pore size distribution may consist of a high percentage of pores between 10 and 100 nm and additionally the presence of pores >100 nm. Such a pore structure may provide performance advantages. For example, the presence of such a pore size distribution can lead to more efficient diffusion (of reactants and products) through the larger pore (transport pores) to and from catalytically active surfaces which reside in the pores sized between 10 and 100 nm. More efficient access and egress for the reactants and products can lead to improvements in catalyst productivity, selectivity, and/or yield.

Following heat treatment of the shaped carbon composite, the resulting shaped porous carbon product comprises the carbonaceous material (e.g., carbon black) and carbonized binder. More generally, the shaped porous carbon product can comprise a carbon agglomerate. Without being bound by any particular theory, it is believed that the carbon agglomerate comprises carbon aggregates or particles that are physically bound or entangled at least in part by the carbonized binder. Moreover, and without being bound by any particular theory, the resulting agglomerate may include chemical bonding of the carbonized binder with the carbon aggregates or particles.

The carbonized binder comprises a carbonization product of a water soluble organic binder as described herein. Carbonizing the binder during preparation of the shaped porous carbon product will reduce the weight of the shaped carbon composite from which it is formed. Accordingly, in various embodiments, the carbonized binder content of the shaped porous carbon product on a dry weight basis is from about 5 wt. % to about 65 wt. %, from about 5 wt. % to about 60 wt. %, from about 5 wt. % to about 50 wt. %, from about 5 wt. % to about 40 wt. %, from about 5 wt. % to about 30 wt. %, from about 10 wt. % to about 65 wt. %, from about 10 wt. % to about 60 wt. %, from about 10 wt. % to about 50 wt. %, from about 10 wt. % to about 40 wt. %, from about 10 wt. % to about 30 wt. %, from about 15 wt. % to about 50 wt. %, from about 15 wt. % to about 40 wt. %, from about 15 wt. % to about 35 wt. %, from about 15 wt. % to about 20 wt. % (e.g., 17 wt. %), from about 25 wt. % to about 40 wt. %, or from about 30 wt. % to about 40 wt. % (e.g., 30 wt. %). The carbonized binder content of the shaped porous carbon product is calculated by the following equation:

$\left\lbrack {1 - \frac{\left( \begin{matrix} {{Weight}\mspace{14mu}{of}\mspace{14mu}{carbonaceous}\mspace{14mu}{material}\mspace{14mu}{used}} \\ {{to}\mspace{14mu}{prepare}\mspace{14mu}{shaped}\mspace{14mu}{porous}\mspace{14mu}{carbon}\mspace{14mu}{product}} \end{matrix}\mspace{14mu} \right)}{\left( {{Dry}\mspace{14mu}{weight}\mspace{14mu}{of}\mspace{14mu}{shaped}\mspace{14mu}{porous}\mspace{14mu}{carbon}\mspace{14mu}{product}} \right)}} \right\rbrack \times 100\%$

The specific surface area (BET surface area), mean pore diameter, and specific pore volume of the shaped porous carbon products are generally comparable to that exhibited by the carbonaceous material (e.g., carbon black) used to prepare the products. However, the preparation process can lead to a reduction or an increase in these characteristics of the products as compared to the carbonaceous material (e.g., about a 10-50% or 10-30% decrease or increase). The properties of the shaped porous carbon products, such as specific surface area and mean pore diameter can be adjusted by selection of the type of carbonaceous material (e.g., carbon black), the type of binder, the concentration of the binder, the amount of solvent (e.g., water) in the carbon-binder mixture, among other parameters. For example, to obtain a shaped porous carbon product having a specific surface area in the range of about 50 m²/g to about 100 m²/g, then a carbon black having a specific surface within or around this range can be selected (e.g., ENSACO 150G, ENSACO 250G, ENSACO 250P from Imerys Graphite & Carbon (TIMCAL) or N115 from Sid Richardson).

Further, selection of the binder can influence these properties as well. To determine the potential effects of a particular binder on the properties of the shaped porous carbon product, the binder can be carbonized alone (e.g., without the carbon black) and then analyzed for the properties of interest. For example, carbonization of a glucose binder can result in a porous material having a broad pore size distribution with a BET specific surface area of approximately 150 m²/g. Thus, selection of a carbon black material such as ENSACO 150G and a glucose binder can result in a shaped porous carbon product having a BET specific surface area greater than that measured for the carbon black material itself.

In various embodiments (e.g., when the carbonaceous material comprises or consists essentially of carbon black), the shaped porous carbon product has a specific surface area have a BET specific surface area that is at least about 5 m²/g, at least about 7 m²/g, or at least about 10 m²/g. For example, the BET specific surface can be in the range of from about 5 m²/g to about 500 m²/g, from about 5 m²/g to about 350 m²/g, from about 5 m²/g to about 250 m²/g, from about 5 m²/g to about 225 m²/g, from about 5 m²/g to about 200 m²/g, from about 5 m²/g to about 175 m²/g, from about 5 m²/g to about 150 m²/g, from about 5 m²/g to about 125 m²/g, from about 5 m²/g to about 100 m²/g, from about 7 m²/g to about 500 m²/g, from about 7 m²/g to about 350 m²/g, from about 7 m²/g to about 250 m²/g, from about 7 m²/g to about 225 m²/g, from about 7 m²/g to about 200 m²/g, from about 7 m²/g to about 175 m²/g, from about 7 m²/g to about 150 m²/g, from about 7 m²/g to about 125 m²/g, from about 7 m²/g to about 100 m²/g, from about 10 m²/g to about 500 m²/g, from about 10 m²/g to about 350 m²/g, from about 10 m²/g to about 250 m²/g, from about 10 m²/g to about 225 m²/g, from about 10 m²/g to about 200 m²/g, from about 10 m²/g to about 175 m²/g, from about 10 m²/g to about 150 m²/g, from about 10 m²/g to about 125 m²/g, or from about 10 m²/g to about 100 m²/g. In various embodiments, the BET specific surface area of the shaped porous carbon black product is in the range of from about 20 m²/g to about 500 m²/g from about 20 m²/g to about 350 m²/g, from about 20 m²/g to about 250 m²/g, from about 20 m²/g to about 225 m²/g, from about 20 m²/g to about 200 m²/g, from about 20 m²/g to about 175 m²/g, from about 20 m²/g to about 150 m²/g, from about 20 m²/g to about 125 m²/g, or from about 20 m²/g to about 100 m²/g, from about 25 m²/g to about 500 m²/g, from about 25 m²/g to about 350 m²/g, from about 25 m²/g to about 250 m²/g, from about 25 m²/g to about 225 m²/g, from about 25 m²/g to about 200 m²/g, from about 25 m²/g to about 175 m²/g, from about 25 m²/g to about 150 m²/g, from about 25 m²/g to about 125 m²/g, from about 25 m²/g to about 100 m²/g, from about 25 m²/g to about 75 m²/g, from about 30 m²/g to about 500 m²/g, from about 30 m²/g to about 350 m²/g, from about 30 m²/g to about 250 m²/g, from about 30 m²/g to about 225 m²/g, from about 30 m²/g to about 200 m²/g, from about 30 m²/g to about 175 m²/g, from about 30 m²/g to about 150 m²/g, from about 30 m²/g to about 125 m²/g, from about 30 m²/g to about 100 m²/g, or from about 30 m²/g to about 70 m²/g. The BET specific surface area of the shaped porous carbon product is determined from nitrogen adsorption data using the Brunauer, Emmett and Teller. See the methods described in J. Am. Chem. Soc. 1938, 60, 309-331 and ASTM Test Methods D3663, D6556 or D4567, which are Standard Test Methods for Surface Area Measurements by Nitrogen Adsorption.

When carbon black is the carbonaceous material, the shaped porous carbon products typically have a mean pore diameter greater than about 5 nm, greater than about 10 nm, greater than about 12 nm, greater than about 14 nm, greater than about 20 nm, greater than about 30 nm, and often greater than about 40 nm. In some embodiments, the mean pore diameter of the shaped porous carbon product is from about 5 nm to about 100 nm, from about 5 nm to about 70 nm, from 5 nm to about 50 nm, from about 5 nm to about 25 nm, from about 10 nm to about 100 nm, from about 10 nm to about 70 nm, from 10 nm to about 50 nm, or from about 10 nm to about 25 nm. In accordance with some embodiments, the mean pore diameter of the shaped porous carbon product is in the range of from about 30 nm to about 100 nm, from about 30 nm to about 90 nm greater, from 30 nm to about 80 nm, from 30 nm to about 70 nm, or from about 30 nm to about 60 nm.

Also, when carbon black is the carbonaceous material, the shaped porous carbon products of the present invention can have specific pore volumes of the pores having a diameter of 1.7 nm to 100 nm as measured by the BJH method that are generally greater than about 0.1 cm³/g, greater than about 0.2 cm³/g, or greater than about 0.3 cm³/g. In various embodiments, the shaped porous carbon products have a specific pore volume of the pores having a diameter of 1.7 nm to 100 nm as measured by the BJH method that is from about 0.1 cm³/g to about 1.5 cm³/g, from about 0.1 cm³/g to about 0.9 cm³/g, from about 0.1 cm³/g to about 0.8 cm³/g, from about 0.1 cm³/g to about 0.7 cm³/g, from about 0.1 cm³/g to about 0.6 cm³/g, from about 0.1 cm³/g to about 0.5 cm³/g, from about 0.2 cm³/g to about 1 cm³/g, from about 0.2 cm³/g to about 0.9 cm³/g, from about 0.2 cm³/g to about 0.8 cm³/g, from about 0.2 cm³/g to about 0.7 cm³/g, from about 0.2 cm³/g to about 0.6 cm³/g, from about 0.2 cm³/g to about 0.5 cm³/g, from about 0.3 cm³/g to about 1 cm³/g, from about 0.3 cm³/g to about 0.9 cm³/g, from about 0.3 cm³/g to about 0.8 cm³/g, from about 0.3 cm³/g to about 0.7 cm³/g, from about 0.3 cm³/g to about 0.6 cm³/g, or from about 0.3 cm³/g to about 0.5 cm³/g. Mean pore diameters and specific pore volumes are determined in accordance with the procedures described in E. P. Barrett, L. G. Joyner, P. P. Halenda, J. Am. Chem. Soc. 1951, 73, 373-380 (BJH method), and ASTM D4222-03(2008) Standard Test Method for Determination of Nitrogen Adsorption and Desorption Isotherms of Catalysts and Catalyst Carriers by Static Volumetric Measurements, which are incorporated herein by reference.

It has been observed that the magnitude of the specific surface area is generally proportional to the concentration of micropores in the shaped porous carbon product structure. In particular, shaped porous carbon products prepared with carbon black generally possess a low concentration of pores having a diameter less than 1.7 nm. Typically, pores having a diameter less than 1.7 nm constitute no more than about 10%, no more than about 5%, no more than about 4%, no more than about 3%, or no more than about 2.5% of the pore volume of the shaped porous carbon product. Similarly, in various embodiments, the pore size distribution of the shaped porous carbon products prepared with carbon black is such that peaks below about 10 nm or about 5 nm are not observed. For example, the shaped porous carbon products can have a pore size distribution such that the peak of the distribution is at a diameter greater than about 5 nm, greater than about 7.5 nm, greater than about 10 nm, greater than about 12.5 nm, greater than about 15 nm, or greater than about 20 nm. Also, the shaped porous carbon product can have a pore size distribution such that the peak of the distribution is at a diameter less than about 100 nm, less than about 90 nm, less than about 80 nm, or less than about 70 nm.

Moreover, shaped porous carbon product prepared with carbon black advantageously exhibits a high concentration of mesopores between about 10 nm to about 100 nm or between about 10 nm to about 50 nm. Accordingly, in various embodiments, at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter in the range of from about 10 nm to about 100 nm. For example, from about 50% to about 95%, from about 50% to about 90%, from about 50% to about 80%, from about 60% to about 95%, from about 60% to about 90%, from about 60% to about 80%, from about 70% to about 95%, from about 70% to about 90%, from about 70% to about 80%, from about 80% to about 95%, or from about 80% to about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter in the range of from about 10 nm to about 100 nm. Also, in various embodiments, at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm. For example, from about 35% to about 80%, from about 35% to about 75%, from about 35% to about 65%, from about 40% to about 80%, from about 40% to about 75%, or from about 40% to about 70% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm.

Typically, the shaped porous carbon product prepared with carbon black exhibits a relatively low concentration of pores less having a diameter that is less than 10 nm, less than 5 nm, or less than 3 nm. For example, no more than about 10%, no more than about 5%, or no more than about 1% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter less than 10 nm, less than 5 nm, or less than 3 nm. In various embodiments, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.1% to about 1%, from about 1% to about 10%, or from about 1% to about 5% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a pore diameter less than 10 nm, less than 5 nm, or less than 3 nm.

The shaped porous carbon products described herein are mechanically strong and stable. Crush strength represents the resistance of a solid to compression, and is an important property in the industrial use of the shaped porous carbon product as described herein. Instruments for measuring the piece crush strength of individual solid particles generally include a dynamometer that measures the force progressively applied to the solid during the advancement of a piston. The applied force increases until the solid breaks and collapses into small pieces and eventually powder. The corresponding value of the collapsing force is defined as piece crush strength and is typically averaged over multiple samples. Standard protocols for measuring crush strength are known in the art. For example, the mechanical strength of the shaped porous carbon product can be measured by piece crush strength test protocols described by ASTM D4179 or ASTM D6175, which are incorporated herein by reference. Some of these test methods are reportedly limited to particles of a defined dimensional range, geometry, or method of manufacture. However, crush strength of irregularly shaped particles and particles of varying dimension and manufacture may nevertheless be adequately measured by these and similar test methods.

In various embodiments, the shaped porous carbon product prepared in accordance with the present invention has a radial piece crush strength of greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 17.6 N/mm (4 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm). In certain embodiments, the radial piece crush strength of the shaped porous carbon product is from about 4.4 N/mm (1 lb/mm) to about 88 N/mm (20 lbs/mm), from about 4.4 N/mm (1 lb/mm) to about 66 N/mm (15 lbs/mm), from about 8.8 N/mm (2 lb/mm) to about 44 N/mm (10 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 20 N/mm (4.5 lbs/mm) to about 88 N/mm (20 lbs/mm), or from about 20 N/mm (4.5 lbs/mm) to about 44 N/mm (10 lbs/mm). In radial piece crush strength measurements, the measured force is relative to the dimension of the solid perpendicular to the applied load, which typically can range from about 0.5 mm to about 20 mm, from about 1 mm to about 10 mm, or from about 1.5 mm to 5 mm. For irregularly shaped porous carbon products, the radial piece crush strength is measured by applying the load perpendicular to the longest dimension of the solid.

Mechanical piece crush strength can also be reported on a basis that is unitless with respect to the dimension of the shaped porous carbon product (e.g., for generally spherically shaped solids or solids having approximately equal transverse dimensions). The shaped porous carbon product prepared in accordance with the present invention typically has a piece crush strength greater than about 22 N (5 lbs), greater than about 36 N (8 lbs), or greater than about 44 N (10 lbs). In various embodiments, shaped porous carbon product may have a piece crush strength from about 22 N (5 lbs) to about 88 N (20 lbs), from about 22 N (5 lbs) to about 66 N (15 lbs), or from about 33 N (7.5 lbs) to about 66 N (15 lbs).

In addition to crush strength, the shaped porous carbon products also exhibit desirable attrition and abrasion resistance characteristics. There are several test methods suitable for determining the attrition and abrasion resistance of the shaped porous carbon products and catalysts produced in accordance with the present disclosure. These methods are a measure of the propensity of the material to produce fines in the course of transportation, handling, and use on stream.

One such method is the attrition index as determined in accordance with ASTM D4058-96 (Standard Test Method for Attrition and Abrasion of Catalysts and Catalyst Carriers), which is a measurement of the resistance of a material (e.g., extrudate or catalyst particle) to attrition wear due to the repeated striking of the particle against hard surfaces within a specified rotating test drum and is incorporated herein by reference. This test method is generally applicable to tablets, extrudates, spheres, granules, pellets as well as irregularly shaped particles typically having at least one dimension larger than about 1.6 mm ( 1/16 inch) and smaller than about 19 mm (¾ inch), although attrition measurements can also be performed on larger size materials. Variable and constant rate rotating cylinder abrasimeters designed according to ASTM D4058-96 are readily available. Typically, the material to be tested is placed in drum of the rotating test cylinder and rolled at from about 55 to about 65 RPM for about 35 minutes. Afterwards, the material is removed from test cylinder and screened on a 20-mesh sieve. The percentage (by weight) of the original material sample that remains on the 20-mesh sieve is referred to as the “percent retained.” The shaped porous carbon products (e.g., extrudates) and catalysts prepared therefrom typically exhibit a rotating drum attrition index as measured in accordance with ASTM D4058-96 or similar test method such that the percent retained is greater than about 85%, greater than about 90%, greater than about 92%, greater than about 95%, greater than about 97%, or greater than about 99% by weight. A percent retained result of greater than about 97% is indicative of materials with exceptional mechanical stability and robust structure particularly desirable for industrial applications.

Abrasion loss (ABL) is an alternate measurement of the resistance of the shaped porous carbon products (e.g., extrudates) and catalysts prepared therefrom. As with the attrition index, the results of this test method can be used as a measure of fines production during the handling, transportation, and use of the material. Abrasion loss is a measurement of the resistance of a material to attrition wear due to the intense horizontal agitation of the particles within the confines of a 30-mesh sieve. Typically, the material to be tested is first de-dusted on a 20-mesh sieve by gently moving the sieve side-to-side at least about 20 times. The de-dusted sample is weighed and then transferred to the inside of a clean, 30-mesh sieve stacked above a clean sieve pan for the collection of fines. The complete sieve stack is then assembled onto a sieve shaker (e.g., RO-Tap RX-29 sieve shaker from W.S. Tyler Industrial Group, Mentor, Ohio), covered securely and shaken for about 30 minutes. The collected fines generated are weighed and divided by the de-dusted sample weight to provide a sample abrasion loss in percent by weight. The shaped porous carbon products (e.g., extrudates) and catalysts prepared therefrom typically exhibit a horizontal agitation sieve abrasion loss of less than about 5%, less than about 3%, less than about 2%, less than about 1%, less than about 0.5%, less than about 0.2%, less than about 0.1%, less than about 0.05%, or less than about 0.03% by weight. An abrasion loss result of less than about 2% is particularly desired for industrial applications.

As previously noted herein, the shaped porous carbon products of the present invention can exhibit a high wettability, which improves catalyst preparation when these products are used as catalyst supports. Applicants have discovered that wettability of the shaped porous products can be enhanced by employing certain pyrolysis (carbonization) conditions as described herein. As used herein, the term “wettability” refers to the rate at which the shaped porous product takes up water. Wettability can be measured using techniques known in the art. For instance, in the context of preparing a catalyst using the shaped porous carbon product as a support, a measurement of the time needed for incipient wetness impregnation can provide a direct indication of the wetting rate of the product. The time needed for incipient wetness impregnation is measured starting at the time when the liquid containing the catalyst active component or precursor thereof is contacted with the catalyst support (i.e., shaped porous carbon product) and ending at the time when no remaining liquid is visible (i.e., when the liquid has been fully absorbed by the support).

In particular, it has been discovered that wettability can be improved by pyrolyzing the shaped carbon composite (i.e., carbonizing the binder) in a heating zone that is maintained at an elevated temperature (e.g., greater than about 400° C. and higher carbonization temperatures within the ranges specified herein) or that includes a series of heating stages (multi-staged) that are each maintained at an elevated temperature (e.g., greater than about 400° C. and higher carbonization temperatures within the ranges specified herein). Shaped porous carbon products pyrolyzed under these temperature conditions exhibit improved wettability as compared to a control product (shaped porous carbon product control 1) that is prepared by an otherwise identical process, but is pyrolyzed in a heating zone where upon introducing the shaped carbon composite to the heating zone, the temperature of the heating zone is ramped from ambient temperature or relatively low temperature (e.g., less than about 100° C.) to the elevated temperature (e.g., about 800° C.). Specifically, the shaped porous carbon product control 1 is prepared by the process described in Example 17 in which the shaped carbon composite (e.g., carbon black extrudate) is heated in a heating zone (e.g., continuous rotary tube furnace) in which the temperature is ramped from ambient to 800° C. under nitrogen atmosphere.

One shaped porous carbon product having improved wettability over the shaped carbon porous control product 1 can be prepared according to the process described in Example 18 in which the shaped carbon composite was pyrolyzed to form the shaped porous carbon product in a continuous rotary kiln maintained at a temperature between approximately 760° C. to 820° C. under nitrogen atmosphere. As such, in some embodiments where a single temperature heating zone (e.g., continuous rotary kiln) is used, the temperature can range from about 750° C. to about 850° C. and the residence time can range from about 30 to about 90 minutes. Alternatively, a shaped porous carbon product having improved wettability over the shaped porous carbon product control 1 can be prepared by a process that includes pyrolyzing the shaped carbon composite in a heating zone that comprises at least two heating stages.

In accordance with these aspects of the present invention, one highly wettable shaped porous carbon product comprises carbon black and a carbonized binder comprising a carbonization product of an organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 25 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and a carbon black content of at least about 35 wt. %, and wherein the shaped porous carbon product has improved wettability over shaped porous carbon product control 1 (prepared according to Example 17).

Another highly wettable shaped porous carbon product of the present invention comprises a carbon agglomerate comprising the carbonaceous material wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 25 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and wherein the shaped porous carbon product has improved wettability over shaped porous carbon product control 1 (prepared according to Example 17).

The shaped porous carbon products and methods for preparing the shaped porous carbon products of the present invention include various combinations of features described herein. For example, in various embodiments, the shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and a carbon black content of at least about 35 wt. %. In other embodiments, the shaped porous carbon product comprises a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm).

The shaped porous carbon product of the present invention may also have a low sulfur content. For example, the sulfur content of the shaped porous carbon product may be no greater than about 1 wt. % or no greater than about 0.1 wt. %.

Features and characteristics including the type of carbonaceous material (e.g., carbon black), the binder, the specific surface area, the specific pore volume, the mean pore diameter, the crush strength, attrition and abrasion resistance and the carbon black content may be independently adjusted or modified within the ranges described herein. Also, shaped porous carbon products may be further defined according to characteristics described herein.

For instance, the shaped porous carbon product can comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder and wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g, a mean pore diameter greater than about 5 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), a carbon black content of at least about 35 wt. %, and a carbonized binder content from about 5 wt. % to about 65 wt. % (e.g., from about 20 wt. % to about 50 wt. %).

In other embodiments, a shaped porous carbon product of the present invention comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and a carbon black content of at least about 35 wt. %, and wherein the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter from 1.7 nm to 100 nm and at least about 35% of the pore volume is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm.

Yet another shaped porous carbon product of the present invention comprises a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and wherein the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter from 1.7 nm to 100 nm and at least about 35% of the pore volume is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm.

One specific series of the shaped porous carbon products which are particularly useful as catalyst supports comprise (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 25 m²/g to about 100 m²/g or from about 30 m²/g to about 75 m²/g, a mean pore diameter greater than about 30 nm (e.g., from about 30 nm to about 75 nm), and a radial piece crush strength greater than about 8.8 N/mm (2 lb/mm). Shaped porous carbon products suitable for use as catalyst supports include those which comprise a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, BET specific surface area from about 25 m²/g to about 100 m²/g or from about 30 m²/g to about 75 m²/g, a mean pore diameter greater than about 30 nm (e.g., in the range of from about 30 nm to about 75 nm), and a radial piece crush strength greater than about 8.8 N/mm (2 lb/mm). The carbon black content of these shaped porous carbon products is typically at least about 50 wt. %, at least about 60 wt. %, at least about 70 wt. %, or at least about 80 wt. %.

Methods of the present invention include various combinations of the features, characteristics, and method steps described herein. For example, various methods for preparing the shaped porous carbon product include mixing and heating water and a water soluble organic binder to form a binder solution, wherein the water and binder are heated to a temperature of at least about 50° C., and wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; mixing carbon black particles with the binder solution to produce a carbon black mixture; forming the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product.

Other methods for preparing the shaped porous carbon product include mixing water, carbon black, and a water soluble organic binder to form a carbon black mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; forming the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product.

Further methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof and wherein the weight ratio of the binder to carbon black in the carbon black mixture is at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1, or at least 1.5:1; forming the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product.

Still other methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof and wherein the water content of the carbon black mixture is no more than about 80% by weight, no more than about 55% by weight, no more than about 40% by weight, or no more than about 25% by weight; forming the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product.

Another method of preparing the shaped porous carbon product by extrusion preferably comprises mixing carbon black particles with an aqueous solution comprising a water soluble organic binder compound selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a polysaccharide, and combinations thereof to produce a carbon black mixture, wherein the carbon black mixture comprises at least about 40 wt. % of the carbon black and at least about 40 wt. % of the binder on a dry basis; forming the carbon black mixture under a pressure of at least 500 kPa (5 bar) to produce a shaped carbon black composite; drying the shaped carbon black material at a temperature in the range of from about room temperature (e.g., about 20° C.) to about 150° C.; and heating the dried shaped carbon black composite to a temperature between about 250° C. and about 800° C. in an oxidative, inert, or reductive atmosphere (e.g., an inert N₂ atmosphere) to carbonize the binder to a water insoluble state and produce the shaped porous carbon product, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm). Typically, the water soluble organic binder compound is selected from the group consisting of a monosaccharide, an oligosaccharide, a polysaccharide, and combinations thereof. The carbon black content of the shape porous carbon product can be at least about 35 wt. % or as described herein. Also, in some embodiments, the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter from 1.7 nm to 100 nm and at least about 35% of the pore volume is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm. The carbon black mixture may optionally be heated during the forming step (e.g., extrusion, pelletizing, pilling, tableting, cold or hot isostatic pressing, calandering, injection molding, 3D printing, drip casting, or other methods) to facilitate the forming of the carbon black mixture into the desired shape.

Additional shaped porous carbon products and methods of preparation of the present invention include any combinations of the features described herein and where features described above are independently substituted or added to the aforementioned embodiments.

The shaped porous carbon products can also be wash-coated or dip-coated onto other materials to prepare structured composite materials. The shaped porous carbon products (at least micron-sized) can be domains on heterogeneous, segregated composite materials (e.g., carbon—ZrO₂ composites or carbon domains hosted by large-pore (mm-sized) ceramic foams) as well as layered or structured materials (e.g., carbon black wash-coats onto inert supports such as steatite, plastic or glass balls).

The shaped porous carbon product of the invention may be further treated thermally or chemically to alter the physical and chemical characteristics of the shaped porous carbon product. For example chemical treatment such as an oxidation may a produce a more hydrophilic surface which may provide advantages for preparing a catalyst (improved wetting and dispersion). Oxidation methods are known in the art, see for example U.S. Pat. Nos. 7,922,805 and 6,471,763. In other embodiments, the shaped porous carbon product has been surface treated using known methods for attaching a functional group to a carbon based substrate. See, e.g., WO2002/018929, WO97/47691, WO99/23174, WO99/31175, WO99/51690, WO2000/022051, and WO99/63007, all of which are incorporated herein by reference. The functional group may be an ionizable group such that when the shaped porous carbon product is subjected to ionizing conditions, it comprises an anionic or cationic moiety. This embodiment is useful when the shaped porous carbon product is used as a separation media in chromatography columns and other separation devices.

Catalyst Compositions and Methods of Preparation

Various aspects of the present invention are also directed to catalyst compositions comprising the shaped porous carbon product as a catalyst support and methods of preparing the catalyst compositions. The shaped porous carbon products of the present invention provide effective dispersion and anchoring of catalytically active components or precursors thereof to the surface of the carbon product. The catalyst compositions of the present invention are suitable for use in long term continuous flow operation phase reactions under demanding reaction conditions such as liquid phase reactions in which the shaped porous carbon product is exposed to reactive solvents such as acids and water at elevated temperatures. The catalyst compositions comprising the shaped porous carbon products of the present invention demonstrate operational stability necessary for commodity applications.

In general, the catalyst compositions of the present invention comprise the shaped porous carbon product as a catalyst support and a catalytically active component or precursor thereof at a surface of the support (external and/or internal surface). In various catalyst compositions of the present invention, the catalytically active component or precursor thereof comprises a metal at a surface of the shaped porous carbon product. In these and other embodiments, the metal comprises at least one metal selected from groups IV, V, VI, VII, VIII, IX, X, XI, XII, and XIII. Some preferred metals include cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. In various embodiments, the metal comprises at least one d-block metal. Some preferred d-block metals are selected from the group consisting of cobalt, nickel, copper, zinc, iron, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold and combinations thereof. Typically, the metal(s) at a surface of the catalyst support may constitute from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10% of the total weight of the catalyst.

In general, the metals may be present in various forms (e.g., elemental, metal oxide, metal hydroxides, metal ions, metalates, polyanions, oligomers or colloidal etc.). Typically, however, the metals are reduced to elemental form during preparation of the catalyst composition or in-situ in the reactor under reaction conditions.

The metal(s) may be deposited on a surface of the shaped porous carbon product according to procedures known in the art including, but not limited to incipient wetness, ion-exchange, deposition-precipitation, coating and vacuum impregnation. When two or more metals are deposited on the same support, they may be deposited sequentially or simultaneously. Multiple impregnation steps are also possible (e.g., dual impregnation of the same metal under different conditions to increase overall metal loading or tune the metal distribution across the shell). In various embodiments, the metal(s) deposited on the shaped porous carbon product for the oxidation catalyst form a shell at least partially covering the surface of the carbon product. In other words, metal deposited on the shaped porous carbon product coats external surfaces of the carbon product. In various embodiments, the metal penetrates surficial pores of the shaped porous carbon product to form a shell layer (“egg shell”) with a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments the shell may be produced sub-surface to produce a 10 μm to about 400 μm sub-surface band containing the catalytically active metals (“egg yolk”). Also structured shells featuring different metal distributions across the shell for the various metals are possible.

In other embodiments, the metal(s) may be deposited on the carbonaceous materials (e.g., carbon black particles) before forming the shaped porous carbon product. Accordingly, in these embodiments, the carbon-binder mixture (e.g., carbon black mixture) may further comprise a metal, such as, for example, a d-block metal. Some preferred d-block metals are selected from the group consisting of cobalt, nickel, copper, zinc, iron, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold and combinations thereof. In various embodiments, the metal comprises at least one metal selected from groups IV, V, VI, VII, VIII, IX, X, XI, XII, and XIII. Preferred metals include cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. Typically, the metal(s) may constitute from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10%. For example, when the metal used is a noble metal, the metal content can be from about 0.25% to about 10% of the total weight of the shaped porous carbon product. Alternatively, when the metal used is a non-noble metal, the metal content can be from about 0.1% to about 50% of the total weight of the shaped porous carbon product.

In various embodiments, following metal deposition, the catalyst composition is optionally dried, for example, at a temperature of at least about 50° C., more typically at least about 120° C. for a period of time of at least about 1 hour, more typically 3 hours or more. Alternatively, the drying may be conducted in a continuous or staged manner where independently controlled temperature zones (e.g., 60° C., 80° C., and 120° C.) are utilized. Typically, drying is initiated below the boiling point of the solvent, e.g., 60° C. and then increased. In these and other embodiments, the catalyst is dried under sub-atmospheric or atmospheric pressure conditions. In various embodiments, the catalyst is reduced after drying (e.g., by flowing 5% H₂ in N₂ at 350° C. for 3 hours). Still further, in these and other embodiments, the catalyst is calcined, for example, at a temperature of at least about 200° C. for a period of time (e.g., at least about 3 hours).

In some embodiments, the catalyst composition of the present invention is prepared by depositing the catalytically active component or precursor thereof subsequent to forming the shaped porous carbon product (i.e., depositing directly on a surface of the shaped porous carbon product). The catalyst composition of the present invention can be prepared by contacting the shaped porous carbon product with a solubilized metal complex or combination of solubilized metal complexes. The heterogeneous mixture of solid and liquids can then be stirred, mixed and/or shaken to enhance the uniformity of dispersion of the catalyst, which, in turn, enables the more uniform deposition of metal(s) on the surface of the support upon removal of the liquids. Following deposition, the metal complex(es) on the shaped porous carbon products are heated and reduced under a reducing agent such as a hydrogen containing gas (e.g., forming gas 5% H₂ and 95% N₂). The temperature at which the heating is conducted generally ranges from about 150° C. to about 600° C., from about 200° C. to about 500° C., or from about 100° C. to about 400° C. Heating is typically conducted for a period of time ranging from about 1 hour to about 5 hours or from about 2 hour to about 4 hours. Reduction may also be carried in the liquid phase. For example, catalyst compositions can be treated in a fixed bed with the liquid containing a reducing agent pumped through the static catalyst.

In other embodiments, the catalyst composition of the present invention is prepared by depositing the catalytically active component or precursor thereof on the carbonaceous material (e.g., carbon black) prior to forming the shaped porous carbon product. In one such method, a slurry of the carbonaceous material with solubilized metal complex(es) is prepared. Carbonaceous material may be initially dispersed in a liquid such as water. Thereafter, the solubilized metal complex(es) may be added to the slurry containing the carbonaceous material. The heterogeneous mixture of solid and liquids can then be stirred, mixed and/or shaken to enhance the uniformity of dispersion of the catalyst, which, in turn, enables the more uniform deposition of metal(s) on the surface of the carbonaceous material upon removal of the liquids. Following deposition, the metal complex(es) on the carbonaceous material is heated and reduced with a reducing agent as described above. The metal-loaded carbonaceous particles can then be formed according to the method described for the shaped porous carbon product. The slurry can also be wash-coated onto inert supports rather than shaped into bulk catalyst pellets.

The catalyst compositions comprising the shaped porous carbon product as a catalyst support can be deployed in various reactor formats, particularly those suited liquid phase medium such as batch slurry, continuous slurry-based stirred tank reactors, cascade of stirred tank reactors, bubble slurry reactor, fixed beds, ebulated beds and other known industrial reactor formats. Accordingly, in various aspects, the present invention is further directed to methods of preparing a reactor vessel for a liquid phase catalytic reaction. In other aspects, the present invention is further directed to methods of preparing a reactor vessel for a gaseous phase catalytic reaction. The method comprises charging the reactor vessel with a catalyst composition comprising the shaped porous carbon product as described herein as a catalyst support. In some embodiments, the reactor vessel is a fixed bed reactor.

Various methods for preparing a catalyst composition in accordance with the present invention include mixing and heating water and a water soluble organic binder to form a binder solution, wherein the water and binder are heated to a temperature of at least about 50° C., and wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; mixing carbon black particles with the binder solution to produce a carbon black mixture; forming the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Other methods include mixing water, carbon black, and a water soluble organic binder to form a carbon black mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; forming the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Further methods for preparing a catalyst composition in accordance with the present invention include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof and wherein the weight ratio of the binder to carbon black in the carbon black mixture is at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1, or at least 1.5:1; forming the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Other methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof and wherein the water content of the carbon black mixture is no more than about 80% by weight, no more than about 55% by weight, no more than about 40% by weight, or no more than about 25% by weight; forming the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder to a water insoluble state and to produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Still further methods include depositing a catalytically active component or precursor thereof on a shaped porous carbon product to produce the catalyst composition, wherein the shaped porous carbon product comprises: (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder and wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g, a mean pore diameter greater than about 5 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), a carbon black content of at least about 35 wt. %, and a carbonized binder content from about 5 wt. % to about 65 wt. % (e.g., from about 20 wt. % to about 50 wt. %).

Catalytic Processes

The catalyst compositions comprising the shaped porous carbon product of the present invention are useful for various catalytic conversions including oxidations, reductions, dehydrations, hydrogenations and other known transformations using appropriate active metals formulations and which can be conducted in gaseous or liquid medium. Accordingly, in further aspects, the present invention is directed to processes for the catalytic conversion of a reactant.

Processes of the present invention comprise contacting a liquid medium comprising the reactant with a catalyst composition comprising the shaped porous carbon product as a catalyst support. In various embodiments, the shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and a carbon black content of at least about 35 wt. %. In other embodiments, the shaped porous carbon product comprises a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm). Typically, the catalyst composition has superior mechanical strength (e.g., mechanical piece crush strength and/or radial piece crush strength) and is stable to the continuous flow of the liquid medium and reaction conditions for at least about 500 hours or about 1,000 hours without substantial loss in catalytic productivity, selectivity, and/or yield.

In addition, it has been surprisingly discovered that the catalyst compositions comprising the shaped porous carbon product of the present invention are highly productive and selective catalysts for a certain of chemical transformations such as the conversion of highly functionalized and/or non-volatile molecules including, but not limited to biorenewably-derived molecules and intermediates for commodity applications.

Catalytic Oxidation

One series of chemical transformations that the catalyst compositions of the present invention are suited for is the selective oxidation of a hydroxyl group to a carboxyl group in a liquid or gaseous reaction medium. For example, one series of chemical transformations that the catalyst compositions of the present invention are especially suited for is the selective oxidation an aldose to an aldaric acid. Accordingly, catalyst compositions of the present invention as described herein can be utilized as oxidation catalysts. Aldoses include, for example, pentoses and hexoses (i.e., C-5 and C-6 monosaccharides). Pentoses include ribose, arabinose, xylose, and lyxose, and hexoses include glucose, allose, altrose, mannose, gulose, idose, galactose, and talose. Accordingly, in various embodiments, the present invention is also directed to a process for the selective oxidation of an aldose to an aldaric acid comprising reacting the aldose with oxygen in the presence of a catalyst composition as described herein to form the aldaric acid. Typically, the catalyst composition comprises at least platinum as a catalytically active component.

The catalyst compositions of the present invention have been found to be especially selective for the oxidation of the glucose to glucaric acid. Accordingly, the present invention is directed to a process for the selective oxidation of glucose to glucaric acid comprising reacting the aldose with oxygen in the presence of a catalyst composition as described herein to form glucaric acid. U.S. Pat. No. 8,669,397, the entire contents of which are incorporated herein by reference, discloses various catalytic processes for the oxidation of glucose to glucaric acid. In general, glucose may be converted to glucaric acid in high yield by reacting glucose with oxygen (e.g., air, oxygen-enriched air, oxygen alone, or oxygen with other constituents substantially inert to the reaction) in the presence of an oxidation catalyst according to the following reaction:

The oxidation can be conducted in the absence of added base (e.g., KOH) or where the initial pH of the reaction medium and/or the pH of reaction medium at any point in the reaction is no greater than about 7, no greater than 7.0, no greater than about 6.5, or no greater than about 6. The initial pH of the reaction mixture is the pH of the reaction mixture prior to contact with oxygen in the presence of an oxidation catalyst. In fact, catalytic selectivity can be maintained to attain glucaric acid yield in excess of about 30%, about 40%, about 50%, about 60% and, in some instances, attain yields in excess of 65% or higher. The absence of added base advantageously facilitates separation and isolation of the glucaric acid, thereby providing a process that is more amenable to industrial application, and improves overall process economics by eliminating a reaction constituent. The “absence of added base” as used herein means that base, if present (for example, as a constituent of a feedstock), is present in a concentration which has essentially no effect on the efficacy of the reaction; i.e., the oxidation reaction is being conducted essentially free of added base. The oxidation reaction can also be conducted in the presence of a weak carboxylic acid, such as acetic acid, in which glucose is soluble. The term “weak carboxylic acid” as used herein means any unsubstituted or substituted carboxylic acid having a pKa of at least about 3.5, more preferably at least about 4.5 and, more particularly, is selected from among unsubstituted acids such as acetic acid, propionic acid or butyric acid, or mixtures thereof.

The oxidation reaction may be conducted under increased oxygen partial pressures and/or higher oxidation reaction mixture temperatures, which tends to increase the yield of glucaric acid when the reaction is conducted in the absence of added base or at a pH below about 7. Typically, the partial pressure of oxygen is at least about 15 pounds per square inch absolute (psia) (104 kPa), at least about 25 psia (172 kPa), at least about 40 psia (276 kPa), or at least about 60 psia (414 kPa). In various embodiments, the partial pressure of oxygen is up to about 1,000 psia (6895 kPa), more typically in the range of from about 15 psia (104 kPa) to about 500 psia (3447 kPa), from about 75 psia (517 kPa) to about 500 psia (3447 kPa), from about 100 psia (689 kPa) to about 500 psia (3447 kPa), from about 150 psia (1034 kPa) to about 500 psia (3447 kPa). Generally, the temperature of the oxidation reaction mixture is at least about 40° C., at least about 60° C., at least about 70° C., at least about 80° C., at least about 90° C., at least about 100° C., or higher. In various embodiments, the temperature of the oxidation reaction mixture is from about 40° C. to about 200° C., from about 60° C. to about 200° C., from about 70° C. to about 200° C., from about 80° C. to about 200° C., from about 80° C. to about 180° C., from about 80° C. to about 150° C., from about 90° C. to about 180° C., or from about 90° C. to about 150° C. Surprisingly, the catalyst compositions comprising the shaped porous carbon product as a catalyst support permit glucose oxidation at elevated temperatures (e.g., from about 100° C. to about 160° C. or from about 125° C. to about 150° C.) without heat degradation of the catalyst. In particular, reactor formats such as a fixed bed reactor which can provide a relatively high liquid throughput in combination with the catalyst compositions comprising the shaped porous carbon product comprising carbon black have been found to permit oxidation at temperatures in excess of 140° C. (e.g., 140° to about 150° C.).

Oxidation of glucose to glucaric acid can also be conducted in the absence of nitrogen as an active reaction constituent. Some processes employ nitrogen compounds such as nitric acid as an oxidant. The use of nitrogen in a form in which it is an active reaction constituent, such as nitrate or nitric acid, results in the need for NO_(x) abatement technology and acid regeneration technology, both of which add significant cost to the production of glucaric acid from these known processes, as well as providing a corrosive environment which may deleteriously affect the equipment used to carry out the process. By contrast, for example, in the event air or oxygen-enriched air is used in the oxidation reaction of the present invention as the source of oxygen, the nitrogen is essentially an inactive or inert constituent. Thus, an oxidation reaction employing air or oxygen-enriched air is a reaction conducted essentially free of nitrogen in a form in which it would be an active reaction constituent.

In accordance with various embodiments, glucose is oxidized to glucaric acid in the presence of a catalyst composition comprising the shaped porous carbon product as a catalyst support described herein and a catalytically active component at a surface of the support. In certain embodiments the catalytically active component comprises platinum. In some embodiments, the catalytically active component comprises platinum and gold.

Applicants have discovered that oxidation catalyst compositions comprising the shaped porous carbon product of the present invention provide unexpectedly greater selectivity and yield for producing glucaric acid from glucose when compared to similar catalysts comprising similar support materials such as activated carbon. In particular, applicants have unexpectedly found that enhanced selectivity and yield for glucaric acid can be achieved by use of an oxidation catalyst composition comprising the shaped porous carbon product as a catalyst support and a catalytically active component comprising platinum and gold at a surface of the shaped porous carbon product (i.e., at a surface of the catalyst support). The enhanced glucaric acid yield is typically at least about 30%, at least about 35%, at least about 40%, at least about, 45%, or at least about 50% (e.g., from about 35% to about 65%, from about 40% to about 65%, or from about 45% to about 65%). Further, the enhanced glucaric acid selectivity is typically at least about 70%, at least about 75%, or at least about 80%.

The oxidation catalyst can include any of the shaped porous carbon products as described herein. For example, in various embodiments, the shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and a carbon black content of at least about 35 wt. %. In other embodiments, the shaped porous carbon product comprises a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm). Another shaped porous carbon product in accordance with the present invention also has a pore volume measured on the basis of pores having a diameter from 1.7 nm to 100 nm and at least about 35% of the pore volume is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm.

Shaped porous carbon products suitable for use as catalyst supports in the catalytic oxidation of glucaric acid include those which comprise (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 25 m²/g to about 100 m²/g or from about 30 m²/g to about 75 m²/g, a mean pore diameter greater than about 30 nm (e.g., from about 30 nm to about 75 nm), and a radial piece crush strength greater than about 8.8 N/mm (2 lb/mm). In some embodiments, shaped porous carbon products used as catalyst supports in the catalytic oxidation of glucaric acid comprise a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, BET specific surface area from about 25 m²/g to about 100 m²/g or from about 30 m²/g to about 75 m²/g, a mean pore diameter greater than about 30 nm (e.g., from about 30 nm to about 75 nm), and a radial piece crush strength greater than about 8.8 N/mm (2 lb/mm). The carbon black content of these shaped porous carbon products is typically at least about 50 wt. %, at least about 60 wt. %, at least about 70 wt. %, or at least about 80 wt. %.

In various embodiments, the catalytically active components or precursors thereof comprising platinum and gold are in the form described in U.S. Patent Application Publication 2011/0306790, the entire contents of which are incorporated herein by reference. This publication describes various oxidation catalysts comprising a catalytically active component comprising platinum and gold, which are useful for the selective oxidation of compositions comprised of a primary alcohol group and at least one secondary alcohol group (e.g., glucose).

In various embodiments, an oxidation catalyst composition according the present invention comprises the shaped porous carbon product as described herein as a catalyst support comprising particles of gold in the form of a gold-containing alloy and particles consisting essentially of platinum (0) as the catalytically active components on a surface of the catalyst support. Typically, the total metal loading of the catalyst composition is about 10 wt. % or less, from about 1 wt. % to about 8 wt. %, from about 1 wt. % to about 5 wt. %, or from about 2 wt. % to about 4 wt. %.

In order to oxidize glucose to glucaric acid, a sufficient amount of the catalytically active component must be present relative to the amount of reactant (i.e., glucose). Accordingly, in a process of the present invention for the oxidation of glucose to glucaric acid as described herein where the catalytically active component comprises platinum, typically the mass ratio of glucose to platinum is from about 10:1 to about 1000:1, from about 10:1 to about 500:1, from about 10:1 to about 200:1, or from about 10:1 to about 100:1.

In various embodiments, the oxidation catalyst of the present invention may be prepared according to the following method. The gold component of the catalyst is typically added to the shaped porous carbon product as a solubilized constituent to enable the formation of a uniform suspension. A base is then added to the suspension in order to create an insoluble gold complex which can be more uniformly deposited onto the support. For example, the solubilized gold constituent is provided to the slurry as gold salt, such as HAuCl4. Upon creation of a well dispersed, heterogeneous mixture, a base is added to the slurry to form an insoluble gold complex which then deposits on the surface of the shaped porous carbon product. Although any base which can affect the formation of an insoluble gold complex is useable, bases such as KOH, NaOH are typically employed. It may be desirable, though not required, to collect the shaped porous carbon product on which has been deposited the insoluble gold complex prior to adding the platinum-containing constituent, which collection can readily be accomplished by any of a variety of means known in the art such as, for example, centrifugation. The collected solids may optionally be washed and then may be heated to dry. Heating may also be employed so as to reduce the gold complex on the support to gold (0). Heating may be conducted at temperatures ranging from about 60° C. (to dry) up to about 500° C. (at which temperature the gold can be effectively reduced). In various embodiments, the heating step may be conducted in the presence of a reducing or oxidizing atmosphere in order to promote the reduction of the complex to deposit the gold onto the support as gold (0). Heating times vary depending upon, for example, the objective of the heating step and the decomposition rate of the base added to form the insoluble complex, and the heating times can range from a few minutes to a few days. More typically, the heating time for the purpose of drying ranges from about 2 to about 24 hours and for reducing the gold complex is on the order of about 1 to about 4 hours.

In various embodiments, the concentration of the shaped porous carbon product in the slurry can be in the range of about 1 to about 100 g of solid/liter of slurry, and in other embodiments the concentration can be in the range of about 5 to about 25 g of solid/liter of slurry.

Mixing of the slurry containing the soluble gold-containing compound is continued for a time sufficient to form at least a reasonably uniform suspension. Appropriate times can range from minutes to a few hours. After addition of the base to convert the gold-containing compound to an insoluble gold-containing complex, the uniformity of the slurry should be maintained for a time sufficient to enable the insoluble complex to be formed and deposit on the shaped porous carbon product. In various embodiments, the time can range from a few minutes to several hours.

Platinum can be added to the shaped porous carbon product or slurry thereof after deposition of gold onto the shaped porous carbon product or after heat treatment to reduce the gold complex on the support to gold (0). Alternatively, the platinum may be added to the shaped porous carbon product or slurry thereof prior to the addition of the solubilized gold compound provided the platinum present on the support is in a form that will not be re-dissolved upon the addition of base used to promote the deposition of gold onto the support. The platinum is typically added as a solution of a soluble precursor or as a colloid. Platinum may be added as a compound selected form the group of platinum (II) nitrate, platinum(IV) nitrate, platinum oxynitrate, platinum (II) acetylacetonate (acac), tetraamineplatinum (II) nitrate, tetraamineplatinum (II) hydrogenphosphate, tetraamineplatinum (II) hydrogencarbonate, tetraamineplatinum (II) hydroxide, H2PtCl6, PtCl4, Na2PtCl4, K2PtCl4, (NH4)2PtCl4, Pt(NH3)4Cl2, mixed Pt(NH3)xCly, K2Pt(OH)6, Na2Pt(OH)6, (NMe4)2Pt(OH)6, and (EA)2Pt(OH)6 where EA=ethanolamine. More preferred compounds include platinum(II) nitrate, platinum(IV) nitrate, platinum(II) acetylacetonate (acac), tetraamine platinum(II) hydroxide, K2PtCl4, and K2Pt(OH)6.

Subsequent to the addition of the platinum compound, the support slurry and platinum-containing compound is dried. Drying may be conducted at room temperature or at a temperature up to about 120° C. More preferably, drying is conducted at a temperature in the range of about 40° C. to about 80° C. and more preferably still at about 60° C. The drying step may be conducted for a period of time ranging from about a few minutes to a few hours. Typically, the drying time is in the range of about 6 hours to about 24 hours. The drying can also be done with continuous or staged temperature increase from about 60° C. to 120° C. on a band calciner or belt dryer (which is preferred for commercial applications).

After drying the support having the platinum compound deposited thereon, it is subjected to at least one thermal treatment in order to reduce platinum deposited as platinum (II) or platinum (IV) to platinum (0). The thermal treatment(s) can be conducted in air or in any reducing or oxidizing atmosphere. In various embodiments the thermal treatment(s) is (are) conducted under a forming gas atmosphere. Alternatively, a liquid reducing agent may be employed to reduce the platinum; for example, hydrazine or formaldehyde or formic acid or salts thereof (e.g., sodium formate) or NaH2PO2 may be employed to effect the requisite reduction of the platinum. The atmosphere under which the thermal treatment is conducted is dependent upon the platinum compound employed, with the objective being substantially converting the platinum on the support to platinum (0).

The temperatures at which the thermal treatment(s) is (are) conducted generally range from about 150° C. to about 600° C. More typically, the temperatures of the thermal treatment(s) range from about 200° C. to about 500° C. and, preferably, the range is from about 200° C. to about 400° C. The thermal treatment is typically conducted for a period of time ranging from about 1 hour to about 8 hours or from about 1 hour to about 3 hours.

In various embodiments, the metal(s) deposited on the shaped porous carbon product for the oxidation catalyst form a shell at least partially covering the surface of the carbon product. In other words, metal deposited on the shaped porous carbon product coats external surfaces of the carbon product. In various embodiments, the metal penetrates surficial pores of the shaped porous carbon product to form a shell layer (“egg shell”) with a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments the shell may be produced sub-surface to produce a 10 μm to about 400 μm sub-surface band containing the catalytically active metals (“egg yolk”).

Catalytic Hydrodeoxygenation

One series of chemical transformations that the catalyst compositions of the present invention are suited for is the hydrodeoxygenation of carbon-hydroxyl groups to carbon-hydrogen groups in a liquid or gaseous reaction medium. For example, one series of chemical transformation that the catalyst compositions of the present invention are especially suited for is the selective halide-promoted hydrodeoxygenation of an aldaric acid or salt, ester, or lactone thereof to a dicarboxylic acid. Accordingly, catalyst compositions of the present invention as described herein can be utilized as hydrodeoxygenation catalysts. As such, the present invention is also directed to a process for the selective halide promoted hydrodeoxygenation of an aldaric acid comprising reacting the aldaric acid or salt, ester, or lactone thereof with hydrogen in the presence of a halogen-containing compound and a catalyst composition as described herein to form a dicarboxylic acid. Typically, the catalyst composition comprises at least one noble metal as a catalytically active component.

The catalyst compositions of the present invention have been found to be especially selective for halide-promoted hydrodeoxygenation of glucaric acid or salt, ester, or lactone thereof to adipic acid. U.S. Pat. No. 8,669,397, referenced above and incorporated herein by reference, describes the chemocatalytic processes for the hydrodeoxygenation of glucaric acid to adipic acid.

Adipic acid or salts and esters thereof may be prepared by reacting, in the presence of a hydrodeoxygenation catalyst and a halogen source, glucaric acid or salt, ester, or lactone thereof, and hydrogen, according to the following reaction:

In the above reaction, glucaric acid or salt, ester, or lactone thereof is converted to an adipic acid product by catalytic hydrodeoxygenation in which carbon-hydroxyl groups are converted to carbon-hydrogen groups. In various embodiments, the catalytic hydrodeoxygenation is hydroxyl-selective wherein the reaction is completed without substantial conversion of the one or more other non-hydroxyl functional group of the substrate.

The halogen source may be in a form selected from the group consisting of ionic, molecular, and mixtures thereof. Halogen sources include hydrohalic acids (e.g., HCl, HBr, HI and mixtures thereof; preferably HBr and/or HI), halide salts, (substituted or unsubstituted) alkyl halides, or molecular (diatomic) halogens (e.g., chlorine, bromine, iodine or mixtures thereof preferably bromine and/or iodine). In various embodiments the halogen source is in diatomic form, hydrohalic acid, or halide salt and, more preferably, diatomic form or hydrohalic acid. In certain embodiments, the halogen source is a hydrohalic acid, in particular hydrogen bromide.

Generally, the molar ratio of halogen to the glucaric acid or salt, ester, or lactone thereof is about equal to or less than about 1. In various embodiments, the mole ratio of halogen to the glucaric acid or salt, ester, or lactone thereof is typically from about 1:1 to about 0.1:1, more typically from about 0.7:1 to about 0.3:1, and still more typically about 0.5:1.

Often, the reaction allows for recovery of the halogen source and catalytic quantities (where molar ratio of halogen to the glucaric acid or salt, ester, or lactone thereof is less than about 1) of halogen can be used, recovered and recycled for continued use as a halogen source.

Generally, the temperature of the hydrodeoxygenation reaction mixture is at least about 20° C., typically at least about 80° C., and more typically at least about 100° C. In various embodiments, the temperature of the hydrodeoxygenation reaction is maintained in the range of from about 20° C. to about 250° C., from about 80° C. to about 200° C., from about 120° C. to about 180° C., or from about 140° C. to 180° C. Typically, the partial pressure of hydrogen is at least about 25 psia (172 kPa), more typically at least about 200 psia (1379 kPa) or at least about 400 psia (2758 kPa). In various embodiments, the partial pressure of hydrogen is from about 25 psia (172 kPa) to about 2500 psia (17237 kPa), from about 200 psia (1379 kPa) to about 2000 psia (13790 kPa), or from about 400 psia (2758 kPa) to about 1500 psia (10343 kPa).

The hydrodeoxygenation reaction may be conducted in the presence of a solvent. Solvents suitable for the selective hydrodeoxygenation reaction include water, carboxylic acids, amides, esters, lactones, sulfoxides, sulfones and mixtures thereof. Preferred solvents include water, mixtures of water and weak carboxylic acid, and weak carboxylic acid. A preferred weak carboxylic acid is acetic acid.

Applicants have discovered that hydrodeoxygenation catalyst compositions comprising the shaped porous carbon product of the present invention provide enhanced selectivity and yield for producing adipic acid. In particular, applicants have unexpectedly found that enhanced selectivity and yield for adipic acid can be achieved by use of a catalyst composition comprising the shaped porous carbon product of the present invention as a catalyst support and a catalytically active component at a surface of the shaped porous carbon product (i.e., at a surface of the catalyst support).

The catalyst can include any of the shaped porous carbon products as described herein. For example, in various embodiments, the shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonization product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 5 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), and a carbon black content of at least about 35 wt. %. In other embodiments, the shaped porous carbon product comprises a carbon agglomerate, wherein the shaped porous carbon product has a diameter of at least about 50 μm, a BET specific surface area from about 20 m²/g to about 500 m²/g or from about 25 m²/g to about 250 m²/g, a mean pore diameter greater than about 5 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm). Another shaped porous carbon product in accordance with the present invention also has a pore volume measured on the basis of pores having a diameter from 1.7 nm to 100 nm and at least about 35% of the pore volume is attributable to pores having a pore diameter in the range of from about 10 nm to about 50 nm.

The catalytically active component or precursor thereof may include noble metals selected from the group consisting of ruthenium, rhodium, palladium, platinum, and combinations thereof. In various embodiments, the hydrodeoxygenation catalyst comprises two or more metals. For example, in some embodiments, the first metal is selected from the group consisting of cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, and platinum (more particularly, ruthenium, rhodium, palladium, and platinum) and the second metal is selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, molybdenum, ruthenium, rhodium, palladium, silver, tungsten, iridium, platinum, and gold (more particularly, molybdenum, ruthenium, rhodium, palladium, iridium, platinum, and gold). In select embodiments, the first metal is selected from the group of platinum, rhodium and palladium, and the second metal is selected from the group consisting of ruthenium, rhodium, palladium, platinum, and gold. In certain embodiments, the first metal is platinum and the second metal is rhodium. In these and other embodiments, the platinum to rhodium molar ratio of the catalyst composition of the present invention is in the range of from about 3:1 to about 1:2 or from about 3:1 to about 1:1.

In various embodiments, the metal(s) deposited on the shaped porous carbon product for the hydrodeoxygenation catalyst form a shell at least partially covering the surface of the carbon product. In other words, metal deposited on the shaped porous carbon product coats external surfaces of the carbon product. In various embodiments, the metal penetrates surficial pores of the shaped porous carbon product to form a shell layer (“egg shell”) with a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments the shell may be produced sub-surface to produce a 10 μm to about 400 μm sub-surface band containing the catalytically active metals (“egg yolk”).

Hydrodeoxygenation of 1,2,6-Hexanetriol

Another chemical transformation that the catalyst compositions of the present invention are advantageously used for is the selective hydrodeoxygenation of 1,2,6-hexanetriol to 1,6-hexanediol (HDO) and 1,2,5,6-hexanetetraol to 1,6-HDO). Accordingly, one process of the present invention is directed to the selective hydrodeoxygenation of 1,2,6-hexanetriol comprising reacting 1,2,6-hexanetriol with hydrogen the presence of a catalyst composition as disclosed herein to form HDO. In embodiments of this process, the catalytically active component of the catalyst composition comprises platinum. In some embodiments, the catalytically active component of the catalyst composition comprises platinum and at least one metal (M2) selected from the group of molybdenum, lanthanum, samarium, yttrium, tungsten, and rhenium. In certain embodiments, the catalytically active component of the catalyst composition comprises platinum and tungsten.

Typically, the total weight of metal(s) is from about 0.1% to about 10%, or from 0.2% to 10%, or from about 0.2% to about 8%, or from about 0.2% to about 5%, of the total weight of the catalyst. In more preferred embodiments the total weight of metal of the catalyst is less than about 4%. The molar ratio of platinum to (M2) may vary, for example, from about 20:1 to about 1:10. In various embodiments, the M1:M2 molar ratio is in the range of from about 10:1 to about 1:5. In still more preferred embodiments, the ratio of M1:M2 is in the range of about 8:1 to about 1:2.

Typically, the conversion of 1,2,6-hexanetriol to HDO is conducted at a temperature in the range of from about 60° C. to about 200° C. or about 120° C. to about 180° C. and a partial pressure of hydrogen in the range of from about 1480 kPa (200 psig) to about 13890 kPa (2000 psig) or from about 3550 kPa (500 psig) to about 13890 kPa (2000 psig).

Catalytic Amination of 1,6-Hexanediol

Furthermore, the catalyst compositions of the present invention are also useful for the selective amination of 1,6-hexanediol (HDO) to 1,6-hexamethylenediamine (HMDA). Accordingly, another process of the present invention is directed to the selective amination of 1,6-hexanediol to 1,6-hexamethylenediamine comprising reacting the HDO with an amine in the presence of a catalyst composition as disclosed herein. In various embodiments of this process, the catalytically active component of the catalyst composition comprises ruthenium.

In some embodiments of this process, the catalytically active component of the catalyst composition comprises ruthenium and optionally a second metal such as rhenium or nickel. One or more other d-block metals, one or more rare earth metals (e.g., lanthanides), and/or one or more main group metals (e.g., Al) may also be present in combination with ruthenium and with ruthenium and rhenium combinations. In select embodiments, the catalytically active phase consists essentially of ruthenium and rhenium. Typically, the total weight of metal(s) is in the range of from about 0.1% to about 10%, from about 1% to about 6%, or from about 1% to about 5% of the total weight of the catalyst composition.

When the catalysts of the present invention comprise ruthenium and rhenium in combination, the molar ratio of ruthenium to rhenium is important. A by-product of processes for converting HDO to HMDA is pentylamine. Pentylamine is an off path by-product of the conversion of HDO to HMDA that cannot be converted to HMDA or to an intermediate which can, on further reaction in the presence of the catalysts of the present invention, be converted to HMDA. However, the presence of too much rhenium can have an adverse effect on the yield of HMDA per unit area time (commonly known as space time yield, or STY). Therefore, the molar ratio of ruthenium:rhenium should be maintained in the range of from about 20:1 to about 4:1. In various embodiments, the ruthenium:rhenium molar ratio is in the range of from about 10:1 to about 4:1 or from about 8:1 to about 4:1. In some embodiments, the ruthenium:rhenium molar ratio of from about 8:1 to about 4:1 produces HMDA in at least 25% yield with an HMDA/pentylamine ratio of at least 20:1, at least 25:1, or at least 30:1.

In accordance with the present invention, HDO is converted to HMDA by reacting HDO with an amine, e.g., ammonia, in the presence of the catalysts of the present invention. Generally, in some embodiments, the amine may be added to the reaction in the form of a gas or liquid. Typically, the molar ratio of ammonia to HDO is at least about 40:1, at least about 30:1, or at least about 20:1. In various embodiments, it is in the range of from about 40:1 to about 5:1, from about 30:1 to about 10:1. The reaction of HDO with amine in the presence of the catalyst composition of the present invention is carried out at a temperature less than or equal to about 200° C. In various embodiments, the catalyst composition is contacted with HDO and amine at a temperature less than or equal to about 100° C. In some embodiments, the catalyst is contacted with HDO and amine at a temperature in the range of from about 100° C. to about 180° C. or from about 140° C. to about 180° C.

Generally, in accordance with the present invention, the reaction is conducted at a pressure not exceeding about 10440 kPa (1500 psig). In various embodiments, the reaction pressure is in the range of from about 1480 kPa (200 psig) to about 10440 kPa (1500 psig). In other embodiments, and a pressure in the range of from about 2860 kPa (400 psig) to about 8380 kPa (1200 psig). In certain preferred embodiments, the pressure in the range of about 2860 kPa (400 psig) to about 7000 kPa (1000 psig). In some embodiments, the disclosed pressure ranges includes the pressure of NH₃ gas and an inert gas, such as N₂. In some embodiments, the pressure of NH₃ gas is in the range of from about 450-1140 kPa (50-150 psig) and an inert gas, such as N₂ is in the range of from about 4930 kPa (700 psig) to about 10100 kPa (1450 psig).

In some embodiments, the catalyst is contacted with HDO and ammonia at a temperature in the range of from about 100° C. to about 180° C. and a pressure in the range of from about 1480 kPa (200 psig) to about 10440 kPa (1500 psig). In other embodiments, the catalyst is contacted with HDO and ammonia at a temperature in the range of about 140° C. to about 180° C. and a pressure in the range of about 2860 kPa (400 psig) to about 8380 kPa (1200 psig). In some embodiments, the disclosed pressure ranges includes the pressure of NH₃ gas and an inert gas, such as N₂. In some embodiments, the pressure of NH₃ gas is in the range of about 450-1140 kPa 50-150 psig and an inert gas, such as N₂ is in the range of about 3550 kPa (500 psig) to about 10100 kPa (1450 psig).

The process of the present invention may be carried out in the presence of hydrogen. Typically, in those embodiments in which the HDO and amine are reacted in the presence of hydrogen and the catalyst of the present invention, the hydrogen partial pressure is equal to or less than about 790 kPa (100 psig).

The conversion of HDO to HMDA can also be conducted in the presence of a solvent. Solvents suitable for use in conjunction with the conversion of HDO to HMDA in the presence of the catalysts of the present invention may include, for example, water, alcohols, esters, ethers, ketones, or mixtures thereof. In various embodiments, the preferred solvent is water.

The chemocatalytic conversion of HDO to HMDA is likely to produce one or more by-products such as, for example, pentylamine and hexylamine. By-products which are subsequently convertible to HMDA by further reaction in the presence of catalysts of the present invention are considered on-path by-products. Other by-products such as, for example, pentylamine and hexylamine are considered off path by-products for the reasons above discussed. In accordance with the present invention, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, or at least 70% of the product mixture resulting from a single pass reaction of HDO with amine (e.g., ammonia) in the presence of the catalysts of the present invention is HMDA.

The product mixture may be separated into one or more products by any suitable methods known in the art. In some embodiments, the product mixture can be separated by fractional distillation under subatmospheric pressures. For example, in some embodiments, HMDA can be separated from the product mixture at a temperature between about 180° C. and about 220° C. The HDO may be recovered from any remaining other products of the reaction mixture by one or more conventional methods known in the art including, for example, solvent extraction, crystallization or evaporative processes. The on-path by-products can be recycled to the reactor employed to produce the product mixture or, for example, supplied to a second reactor in which the on path by-products are further reacted with ammonia in the presence of the catalysts of the present invention to produce additional HMDA.

EMBODIMENTS

For further illustration, additional non-limiting embodiments of the present disclosure are set forth below.

Embodiment A1 is a process for preparing a shaped porous carbon product, the process comprising mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises at least two heating stages that are each maintained at an approximately constant temperature and the temperature of each stage differs by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. with the temperature increasing from one stage to the next.

Embodiment A2 is the process of embodiment Al wherein the temperature of each stage differs by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

Embodiment A3 is the process of embodiment A1 or A2 wherein the heating zone comprises at least three, at least four, at least five, or at least six heating stages that are each maintained at an approximately constant temperature and the temperature of each stage independently differs by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C. from the preceding stage.

Embodiment A4 is a process for preparing a shaped porous carbon product, the process comprising mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises: (1) a first heating stage where the shaped carbon composite is heated at a first temperature; and (2) a second heating stage where the shaped carbon composite is heated at a second temperature and wherein the first and second temperature are each approximately constant and the second temperature is greater than the first temperature by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C.

Embodiment A5 is the process of embodiment A4 wherein the temperature of the first heating stage temperature and the second stage heating stage differ by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

Embodiment A6 is the process of embodiment A4 or A5 wherein the heating zone comprises a third heating stage where the shaped carbon composite is heated at a third temperature that is approximately constant and is greater than the second heating stage temperature by at least about 50° C., at least about 100° C., at least about 150° C., at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., or at least about 400° C.

Embodiment A7 is the process of embodiment A6 wherein the temperature of the second heating stage temperature and the third stage heating stage temperature differ by from about 50° C. to about 500° C., from about 100° C. to about 500° C., from about 200° C. to about 500° C., from about 300° C. to about 500° C., from about 50° C. to about 400° C., from about 100° C. to about 400° C., from about 150° C. to about 400° C., from about 200° C. to about 400° C., from about 300° C. to about 400° C., from about 50° C. to about 300° C., from about 100° C. to about 300° C., from about 150° C. to about 300° C., or from about 200° C. to about 300° C.

Embodiment A8 is the process of any one of embodiments A1 to A7 wherein the heating zone comprises a multi-stage continuous rotary kiln.

Embodiment A9 is a process for preparing a shaped porous carbon product, the process comprising mixing water, a carbonaceous material, and an organic binder to form a carbonaceous material mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbonaceous material mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the heating zone comprises a continuous rotary kiln.

Embodiment A10 is the process of any one of embodiments A1 to A9 wherein the process further comprises drying the shaped carbon composite at a temperature from about 90° C. to about 150° C., from about 100° C. to about 150° C., or from about 100° C. to about 140° C., wherein the water content of the shaped carbon composite after drying is no greater than about 15 wt. %, no greater than about 12 wt. %, or no greater than about 10 wt. %.

Embodiment A11 is a process for preparing a shaped porous carbon product, the process comprising mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) a water soluble polymer; forming the carbon-binder mixture to produce a shaped carbon composite; drying the shaped carbon composite at a temperature from about 90° C. to about 150° C., from about 100° C. to about 150° C., or from about 100° C. to about 140° C., wherein the water content of the shaped carbon composite after drying is no greater than about 15 wt. %, no greater than about 12 wt. %, or no greater than about 10 wt. %; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

Embodiment A12 is the process of embodiment A10 or A11 wherein the water content of the shaped carbon composite after drying is from about 2 wt. % to about 15 wt. %, from about 2 wt. % to about 12 wt. %, from about 2 wt. % to about 10 wt. %, from about 4 wt. % to about 15 wt. %, from about 4 wt. % to about 12 wt. %, from about 4 wt. % to about 10 wt. %, from about 5 wt. % to about 15 wt. %, from about 5 wt. % to about 12 wt. %, or from about 5 wt. % to about 10 wt. %.

Embodiment A13 is the process of any one of embodiments A10 to A12 wherein drying is conducted over a period of time that is no more than about 120 minutes, no more than about 90 minutes, or no more than about 75 minutes, or from about 30 minutes to about 120 minutes, from about 30 minutes to about 90 minutes, from about 30 minutes to about 75 minutes, from about 60 minutes to about 120 minutes, or from about 60 minutes to about 90 minutes.

Embodiment A14 is the process of any one of embodiments A10 to A13 wherein drying is performed using a continuous belt dryer.

Embodiment A15 is the process of any one of embodiments A1 to A14 wherein the binder comprises a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof.

Embodiment A16 is the process of any one of embodiments A1 to A14 wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a water soluble polymer.

Embodiment A17 is a process for preparing a shaped porous carbon product, the process comprising mixing water, a carbonaceous material, and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) a water soluble polymer, wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity of no greater than about 500 mPa·s, no greater than about 400 mPa·s, no greater than about 300 mPa·s, no greater than about 200 mPa·s, no greater than about 100 mPa·s, no greater than about 75 mPa·s, or no greater than about 50 mPa·s at 25° C. and/or the water soluble polymer has a number average molecular weight (M_(n)) that is no greater than about 50,000 g/mol, no greater than about 40,000 g/mol, no greater than about 30,000 g/mol, no greater than about 25,000 g/mol, or no greater than about 20,000 g/mol; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product.

Embodiment A18 is the process of embodiment A17 wherein the process further comprises drying the shaped carbon composite at a temperature from about 90° C. to about 150° C., wherein the water content of the shaped carbon composite after drying is no greater than about 15 wt. %, no greater than about 12 wt. %, or no greater than about 10 wt. %.

Embodiment A19 is the process of embodiment A17 or A18 wherein the water content of the shaped carbon composite after drying is from about 2 wt. % to about 15 wt. %, from about 2 wt. % to about 12 wt. %, from about 2 wt. % to about 10 wt. %, from about 4 wt. % to about 15 wt. %, from about 4 wt. % to about 12 wt. %, from about 4 wt. % to about 10 wt. %, from about 5 wt. % to about 15 wt. %, from about 5 wt. % to about 12 wt. %, or from about 5 wt. % to about 10 wt. %.

Embodiment A20 is the process of any one of embodiments A17 to A19 wherein drying is performed using a continuous belt dryer.

Embodiment A21 is the process of any one of embodiments A17 to A20 wherein drying is conducted over a period of time that is no more than about 120 minutes, no more than about 90 minutes, or no more than about 75 minutes, or from about 30 minutes to about 120 minutes, from about 30 minutes to about 90 minutes, from about 30 minutes to about 75 minutes, from about 60 minutes to about 120 minutes, or from about 60 minutes to about 90 minutes.

Embodiment A22 is the process of any one of embodiments A1 to A21 wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity of no greater than about 500 mPa·s, no greater than about 400 mPa·s, no greater than about 300 mPa·s, no greater than about 200 mPa·s, no greater than about 100 mPa·s, no greater than about 75 mPa·s, or no greater than about 50 mPa·s at 25° C.

Embodiment A23 is the process of any one of embodiments A1 to A21 wherein a 2 wt. % aqueous solution or a 5 wt. % aqueous solution of the water soluble polymer has a viscosity that is from about 2 to about 500 mPa·s, from about 2 to about 400 mPa·s, from about 2 to about 300 mPa·s, from about 2 to about 200 mPa·s, from about 2 to about 150 mPa·s, from about 2 to about 100 mPa·s, from about 2 to about 75 mPa·s, or from about 2 to about 50 mPa·s at 25° C.

Embodiment A24 is the process of any one of embodiments A1 to A23 wherein the water soluble polymer has a number average molecular weight (M_(n)) that is no greater than about 50,000 g/mol, no greater than about 40,000 g/mol, no greater than about 30,000 g/mol, no greater than about 25,000 g/mol, or no greater than about 20,000 g/mol.

Embodiment A25 is the process of any one of embodiments A1 to A23 wherein the water soluble polymer has a number average molecular weight (M_(n)) that is from about 2,000 to about 50,000 g/mol, from about 5,000 to about 40,000 g/mol, from about 5,000 to about 30,000 g/mol, from about 5,000 to about 25,000 g/mol, from about 5,000 to about 20,000 g/mol, from about 10,000 to about 50,000 g/mol, from about 10,000 to about 40,000 g/mol, from about 10,000 to about 30,000 g/mol, from about 10,000 to about 25,000 g/mol, or from about 10,000 to about 20,000 g/mol.

Embodiment A26 is the process of embodiment A1 to A25 wherein the weight ratio of (i) the saccharide to (ii) the water soluble polymer is from about 5:1 to about 100:1, from about 5:1 to about 50:1, 10:1 to about 40:1, from about 10:1 to about 30:1, from about 10:1 to about 25:1, from about 10:1 to about 20:1, from about 20:1 to about 30:1, or from about 25:1 to about 30:1

Embodiment A27 is the process of any one of embodiments A1 to A26 wherein the carbonaceous material is selected from the group consisting of activated carbon, carbon black, graphite, and combinations thereof.

Embodiment A28 is the process of any one of embodiments A1 to A26 wherein the carbonaceous material comprises carbon black.

Embodiment A29 is the process of any one of embodiments A1 to A28 wherein the shaped carbon composite is heated to a final temperature of at least about 400° C., at least about 500° C., at least about 600° C., at least about 700° C., or at least about 800° C. in the heating zone.

Embodiment A30 is the process of any one of embodiments A1 to A28 wherein the shaped carbon composite is heated to a final temperature of from about 400° C. to about 1,000° C., from about 400° C. to about 900° C., from about 400° C. to about 850° C., from about 400° C. to about 800° C., from about 500° C. to about 850° C., from about 500° C. to about 800° C., from about 500° C. to about 700° C., from about 600° C. to about 850° C. or from about 600° C. to about 800° C. in the heating zone.

Embodiment A31 is the process of any one of embodiments A1 to A30 wherein the heating zone comprises a multi-stage continuous rotary kiln.

Embodiment A32 is the process of any one of embodiments A1 to A31 wherein the shaped carbon composite is heated in an inert or oxidative atmosphere.

Embodiment A33 is the process of embodiment A32 wherein the atmosphere is an inert atmosphere.

Embodiment A34 is the process of any one of embodiments A1 to A33 wherein the shaped carbon composite is formed by extruding the carbon-binder mixture.

Embodiment A35 is the process of any one of embodiments A1 to A34 wherein the weight ratio of the binder to carbonaceous material in the carbon-binder mixture is at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1, or at least 1.5:1.

Embodiment A36 is the process of any one of embodiments A1 to A34 wherein the weight ratio of binder to carbonaceous material in the carbon-binder mixture is from about 1:4 to about 3:1, from about 1:4 to about 1:1, from about 1:3 to about 2:1, from about 1:3 to about 1:1, or about 1:1.

Embodiment A37 is the process of any one of embodiments A1 to A36 wherein the carbonaceous material content of the carbon-binder mixture is at least about 35 wt. %, at least about 40 wt. %, at least about 45 wt. %, at least about 50 wt. %, at least about 55 wt. %, at least about 60 wt. %, at least about 65 wt. %, or at least about 70 wt. % on a dry weight basis.

Embodiment A38 is the process of any one of embodiments A1 to A36 wherein the carbonaceous material content of the carbon-binder mixture is from about 35 wt. % to about 80 wt. %, from about 35 wt. % to about 75 wt. %, from about 40 wt. % to about 80 wt. %, or from about 40 wt. % to about 75 wt. % on a dry weight basis.

Embodiment A39 is the process of any one of embodiments A1 to A38 wherein the concentration of the binder in the carbon-binder mixture is at least about 10 wt. %, at least about 20 wt. %, at least about 25 wt. %, at least about 30 wt. %, at least about 35 wt. %, at least about 40 wt. %, or at least 45 wt. % binder on a dry weight basis.

Embodiment A40 is the process of any one of embodiments A1 to A38 wherein the concentration of the binder in the carbon-binder mixture is from about 10 wt. % to about 50 wt. %, from about 10 wt. % to about 45 wt. %, from about 15 wt. % to about 50 wt. %, from about 20 wt. % to about 50 wt. %, or from about 20 wt. % to about 45 wt. % on a dry weight basis.

Embodiment A41 is the process of any one of embodiments A1 to A40 wherein the water content of the carbon-binder mixture is no more than about 80% by weight, no more than about 55% by weight, no more than about 40% by weight, or no more than about 25% by weight.

Embodiment A42 is the process of any one of embodiments A1 to A40 wherein the water content of the carbon-binder mixture is from about 5 wt. % to about 80 wt. %, from about 5 wt. % to about 55 wt. %, from about 5 wt. % to about 40 wt. % or from about 5 wt. % to about 25 wt. %.

Embodiment A43 is the process of any one of embodiments A1 to A42 wherein the binder comprises a monosaccharide.

Embodiment A44 is the process of any one of embodiments A1 to A43 wherein the monosaccharide is selected from the group consisting of glucose, fructose, hydrate thereof, syrup thereof, and combinations thereof.

Embodiment A45 is the process of any one of embodiments A1 to A44 wherein the binder comprises a disaccharide.

Embodiment A46 is the process of any one of embodiments A1 to A45 wherein the disaccharide is selected from the group consisting of maltose, sucrose, syrup thereof, and combinations thereof.

Embodiment A47 is the process of any one of embodiments A1 to A46 wherein the water soluble polymer comprises a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof.

Embodiment A48 is the process of any one of embodiments A1 to A47 wherein the binder comprises a polymeric carbohydrate, derivative of a polymeric carbohydrate, or any combination thereof.

Embodiment A49 is the process of embodiment A47 or A48 wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises a cellulosic compound.

Embodiment A50 is the process of embodiment A49 wherein the cellulosic compound is selected from the group consisting of methylcellulose, ethylcellulose, ethylmethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, methylhydroxyethylcellulose, ethylhydroxyethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, and mixtures thereof.

Embodiment A51 is the process of embodiment A49 wherein the cellulosic compound comprises hydroxyethylcellulose.

Embodiment A52 is the process of any one of embodiments A47 to A51 wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate derivative is selected from the group consisting of alginic acid, pectin, aldonic acids, aldaric acids, uronic acids, sugar alcohols, and salts, oligomers, and polymers thereof.

Embodiment A53 is the process of any one of embodiments A47 to A52 wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises a starch.

Embodiment A54 is the process of any one of embodiments A47 A53 wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises a soluble gum.

Embodiment A55 is the process of any one of embodiments A47 to A54, wherein the binder comprises a non-carbohydrate synthetic polymer.

Embodiment A56 is the process of any one of embodiments A47 to A55 wherein the non-carbohydrate synthetic polymer is selected from the group consisting of polyacrylic acid, polyvinyl alcohols, polyvinylpyrrolidones, polyvinyl acetates, polyacrylates, polyethers, and copolymers derived therefrom.

Embodiment A57 is the process of any one of embodiments A1 to A56 wherein the binder comprises a saccharide selected from the group consisting of glucose, fructose or hydrate thereof and a water soluble polymer selected from the group consisting of hydroxyethylcellulose, methylcellulose, and starch.

Embodiment A58 is the process of any one of embodiments A1 to A57 wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g, from about 20 m²/g to about 350 m²/g, from about 20 m²/g to about 250 m²/g, from about 20 m²/g to about 225 m²/g, from about 20 m²/g to about 200 m²/g, from about 20 m²/g to about 175 m²/g, from about 20 m²/g to about 150 m²/g, from about 20 m²/g to about 125 m²/g, or from about 20 m²/g to about 100 m²/g, from about 25 m²/g to about 500 m²/g, from about 25 m²/g to about 350 m²/g, from about 25 m²/g to about 250 m²/g, from about 25 m²/g to about 225 m²/g, from about 25 m²/g to about 200 m²/g, from about 25 m²/g to about 175 m²/g, from about 25 m²/g to about 150 m²/g, from about 25 m²/g to about 125 m²/g, from about 25 m²/g to about 100 m²/g, from about 30 m²/g to about 500 m²/g, from about 30 m²/g to about 350 m²/g, from about 30 m²/g to about 250 m²/g, from about 30 m²/g to about 225 m²/g, from about 30 m²/g to about 200 m²/g, from about 30 m²/g to about 175 m²/g, from about 30 m²/g to about 150 m²/g, from about 30 m²/g to about 125 m²/g, or from about 30 m²/g to about 100 m²/g.

Embodiment A59 is the process of any one of embodiments A1 to A58 wherein the shaped porous carbon product has a mean pore diameter greater than about 5 nm, greater than about 10 nm, greater than about 12 nm, or greater than about 14 nm.

Embodiment A60 is the process of any one of embodiments A1 to A58 wherein the shaped porous carbon product has a mean pore diameter from about 5 nm to about 100 nm, from about 5 nm to about 70 nm, from 5 nm to about 50 nm, from about 5 nm to about 25 nm, from about 10 nm to about 100 nm, from about 10 nm to about 70 nm, from 10 nm to about 50 nm, or from about 10 nm to about 25 nm.

Embodiment A61 is the process of any one of embodiments A1 to A60 wherein the shaped porous carbon product has a specific pore volume of the pores having a diameter of 1.7 nm to 100 nm as measured by the BJH process that is greater than about 0.1 cm³/g, greater than about 0.2 cm³/g, or greater than about 0.3 cm³/g.

Embodiment A62 is the process of any one of embodiments A1 to A60 wherein the shaped porous carbon product has a specific pore volume of the pores having a diameter of 1.7 nm to 100 nm as measured by the BJH process that is from about 0.1 cm³/g to about 1.5 cm³/g, from about 0.1 cm³/g to about 0.9 cm³/g, from about 0.1 cm³/g to about 0.8 cm³/g, from about 0.1 cm³/g to about 0.7 cm³/g, from about 0.1 cm³/g to about 0.6 cm³/g, from about 0.1 cm³/g to about 0.5 cm³/g, from about 0.2 cm³/g to about 1 cm³/g, from about 0.2 cm³/g to about 0.9 cm³/g, from about 0.2 cm³/g to about 0.8 cm³/g, from about 0.2 cm3/g to about 0.7 cm³/g, from about 0.2 cm³/g to about 0.6 cm³/g, from about 0.2 cm³/g to about 0.5 cm³/g, from about 0.3 cm³/g to about 1 cm³/g, from about 0.3 cm³/g to about 0.9 cm³/g, from about 0.3 cm³/g to about 0.8 cm³/g, from about 0.3 cm³/g to about 0.7 cm³/g, from about 0.3 cm³/g to about 0.6 cm³/g, or from about 0.3 cm³/g to about 0.5 cm³/g.

Embodiment A63 is the process of any one of embodiments A1 to A62 wherein at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 50 nm.

Embodiment A64 is the process of any one of embodiments A1 to A62 wherein from about 35% to about 80%, from about 35% to about 75%, from about 35% to about 65%, from about 40% to about 80%, from about 40% to about 75%, or from about 40% to about 70% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 50 nm.

Embodiment A65 is the process of any one of embodiments A1 to A64 wherein at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 100 nm.

Embodiment A66 is the process of any one of embodiments A1 to A64 wherein from about 50% to about 95%, from about 50% to about 90%, from about 50% to about 80%, from about 60% to about 95%, from about 60% to about 90%, from about 60% to about 80%, from about 70% to about 95%, from about 70% to about 90%, from about 70% to about 80%, from about 80% to about 95%, or from about 80% to about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 100 nm.

Embodiment A67 is the process of any one of embodiments A1 to A66 wherein no more than about 10%, no more than about 5%, or no more than about 1% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter less than 3 nm.

Embodiment A68 is the process of any one of embodiments A1 to A66 wherein from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.1% to about 1%, from about 1% to about 10%, or from about 1% to about 5% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter less than 3 nm.

Embodiment A69 is the process of any one of embodiments A1 to A68 wherein the shaped porous carbon product has a pore size distribution such that the peak of the distribution is at a diameter greater than about 5 nm, greater than about 7.5 nm, greater than about 10 nm, greater than about 12.5 nm, greater than about 15 nm, or greater than about 20 nm.

Embodiment A70 is the process of any one of embodiments A1 to A69 wherein the shaped porous carbon product has a pore size distribution such that the peak of the distribution is at a diameter less than about 100 nm, less than about 90 nm, less than about 80 nm, or less than about 70 nm.

Embodiment A71 is the process of any one of embodiments A1 to A70 wherein the shaped porous carbon product has a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm).

Embodiment A72 is the process of any one of embodiments A1 to A70 wherein the shaped porous carbon product has a radial piece crush strength from about 4.4 N/mm (1 lb/mm) to about 88 N/mm (20 lbs/mm), from about 4.4 N/mm (1 lb/mm) to about 66 N/mm (15 lbs/mm), from about 8.8 N/mm (2 lb/mm) to about 44 N/mm (10 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 20 N/mm (4.5 lbs/mm) to about 88 N/mm (20 lbs/mm), or from about 20 N/mm (4.5 lbs/mm) to about 44 N/mm (10 lbs/mm).

Embodiment A73 is the process of any one of embodiments A1 to A72 wherein the shaped porous carbon product has a mechanical piece crush strength greater than about 22 N (5 lbs), greater than about 36 N (8 lbs), or greater than about 44 N (10 lbs).

Embodiment A74 is the process of any one of embodiments A1 to A72 wherein the shaped porous carbon product has a mechanical piece crush strength from about 22 N (5 lbs) to about 88 N (20 lbs), from about 22 N (5 lbs) to about 66 N (15 lbs), or from about 33 N (7.5 lbs) to about 66 N (15 lbs).

Embodiment A75 is the process of any one of embodiments A1 to A74 wherein the shaped porous carbon product has a diameter of at least about 50 μm, at least about 500 μm, at least about 1,000 μm, or at least about 10,000 μm.

Embodiment A76 is the process of any one of embodiments A1 to A75 wherein the shaped porous carbon product has a carbonaceous material content of at least about 35 wt. %, at least about 40 wt. %, at least about 45 wt. %, at least about 50 wt. %, at least about 55 wt. %, at least about 60 wt. %, at least about 65 wt. %, or at least about 70 wt. %.

Embodiment A77 is the process of any one of embodiments A1 to A75 wherein the shaped porous carbon product has a carbonaceous material content from about 35 wt. % to about 80 wt. %, from about 35 wt. % to about 75 wt. %, from about 40 wt. % to about 80 wt. %, or from about 40 wt. % to about 75 wt. %.

Embodiment A78 is the process of any one of embodiments A1 to A77 wherein the shaped porous carbon product has a carbonized binder content from about 10 wt. % to about 50 wt. %, from about 20 wt. % to about 50 wt. %, from about 25 wt. % to about 40 wt. %, or from about 25 wt. % to about 35 wt. %.

Embodiment A79 is the process of any one of embodiments A1 to A78 wherein the water soluble polymer constitutes no more than about 5 wt. %, no more than about 4 wt. %, no more than about 3 wt. %, no more than about 2 wt. % based on the weight of the water, saccharide and water soluble polymer mixed with the carbonaceous material.

Embodiment A80 is the process of any one of embodiments A1 to A79 wherein the water soluble polymer constitutes no more than about 5 wt. %, no more than about 4 wt. %, no more than about 3 wt. %, or no more than about 2 wt. % based on the weight of the water, saccharide and water soluble polymer mixed with the carbonaceous material.

Embodiment A81 is the process of any one of embodiments A1 to A79 wherein the water soluble polymer constitutes from about 0.5 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, from about 0.5 wt. % to about 3 wt. %, from about 0.5 wt. % to about 2 wt. %, from about 1 wt. % to about 5 wt. %, from about 1 wt. % to about 4 wt. %, from about 1 wt. % to about 3 wt. %, or from about 1 wt. % to about 2 wt. % based on the weight of the water, saccharide and water soluble polymer mixed with the carbonaceous material.

Embodiment B1 is a shaped porous carbon product comprising: carbon black and a carbonized binder comprising a carbonization product of an organic binder, wherein the shaped porous carbon product has a BET specific surface area from about 25 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and a carbon black content of at least about 35 wt. %, and wherein the shaped porous carbon product has improved wettability as compared to shaped porous carbon product control 1.

Embodiment B2 is a highly wettable shaped porous carbon product comprising a carbon agglomerate comprising a carbonaceous material wherein the shaped porous carbon product has a mean diameter of at least about 50 μm, a BET specific surface area from about 25 m²/g to about 500 m²/g, a mean pore diameter greater than about 10 nm, a specific pore volume greater than about 0.1 cm³/g, and a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm), greater than about 8.8 N/mm (2 lbs/mm), greater than about 13.3 N/mm (3 lbs/mm), greater than about 15 N/mm (3.4 lbs/mm), greater than about 17 N/mm (3.8 lbs/mm), or greater than about 20 N/mm (4.5 lbs/mm), and wherein the shaped porous carbon product has improved wettability as compared to shaped porous carbon product control 1.

Embodiment B3 is the shaped porous carbon product of embodiment B2 wherein the carbonaceous material is selected from the group consisting of activated carbon, carbon black, graphite, and combinations thereof.

Embodiment B4 is the shaped porous carbon product of embodiment B2 wherein the carbonaceous material comprises carbon black.

Embodiment B5 is the shaped porous carbon product of any one of embodiments B1 to B4 wherein the shaped porous carbon product has a BET specific surface area from about 20 m²/g to about 500 m²/g, from about 20 m²/g to about 350 m²/g, from about 20 m²/g to about 250 m²/g, from about 20 m²/g to about 225 m²/g, from about 20 m²/g to about 200 m²/g, from about 20 m²/g to about 175 m²/g, from about 20 m²/g to about 150 m²/g, from about 20 m²/g to about 125 m²/g, or from about 20 m²/g to about 100 m²/g, from about 25 m²/g to about 500 m²/g, from about 25 m²/g to about 350 m²/g, from about 25 m²/g to about 250 m²/g, from about 25 m²/g to about 225 m²/g, from about 25 m²/g to about 200 m²/g, from about 25 m²/g to about 175 m²/g, from about 25 m²/g to about 150 m²/g, from about 25 m²/g to about 125 m²/g, from about 25 m²/g to about 100 m²/g, from about 30 m²/g to about 500 m²/g, from about 30 m²/g to about 350 m²/g, from about 30 m²/g to about 250 m²/g, from about 30 m²/g to about 225 m²/g, from about 30 m²/g to about 200 m²/g, from about 30 m²/g to about 175 m²/g, from about 30 m²/g to about 150 m²/g, from about 30 m²/g to about 125 m²/g, or from about 30 m²/g to about 100 m²/g.

Embodiment B6 is the shaped porous carbon product of any one of embodiments B1 to B5 wherein the shaped porous carbon product has a mean pore diameter greater than about 5 nm, greater than about 10 nm, greater than about 12 nm, or greater than about 14 nm.

Embodiment B7 is the shaped porous carbon product of any one of embodiments B1 to B5 wherein the shaped porous carbon product has a mean pore diameter from about 5 nm to about 100 nm, from about 5 nm to about 70 nm, from 5 nm to about 50 nm, from about 5 nm to about 25 nm, from about 10 nm to about 100 nm, from about 10 nm to about 70 nm, from 10 nm to about 50 nm, or from about 10 nm to about 25 nm.

Embodiment B8 is the shaped porous carbon product of any one of embodiments B1 to B7 wherein the shaped porous carbon product has a specific pore volume of the pores having a diameter of 1.7 nm to100 nm as measured by the BJH process that is greater than about 0.1 cm³/g, greater than about 0.2 cm³/g, or greater than about 0.3 cm³/g.

Embodiment B9 is the shaped porous carbon product of any one of embodiments B1 to B7 wherein the shaped porous carbon product has a specific pore volume of the pores having a diameter of 1.7 nm to 100 nm as measured by the BJH process that is from about 0.1 cm³/g to about 1.5 cm³/g, from about 0.1 cm³/g to about 0.9 cm³/g, from about 0.1 cm³/g to about 0.8 cm³/g, from about 0.1 cm³/g to about 0.7 cm³/g, from about 0.1 cm³/g to about 0.6 cm³/g, from about 0.1 cm³/g to about 0.5 cm³/g, from about 0.2 cm³/g to about 1 cm³/g, from about 0.2 cm³/g to about 0.9 cm³/g, from about 0.2 cm³/g to about 0.8 cm³/g, from about 0.2 cm³/g to about 0.7 cm³/g, from about 0.2 cm³/g to about 0.6 cm³/g, from about 0.2 cm³/g to about 0.5 cm³/g, from about 0.3 cm³/g to about 1 cm³/g, from about 0.3 cm³/g to about 0.9 cm³/g, from about 0.3 cm³/g to about 0.8 cm³/g, from about 0.3 cm³/g to about 0.7 cm³/g, from about 0.3 cm³/g to about 0.6 cm³/g, or from about 0.3 cm³/g to about 0.5 cm3/g.

Embodiment B10 is the shaped porous carbon product of any one of embodiments B1 to B9 wherein at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 50 nm.

Embodiment B11 is the shaped porous carbon product of any one of embodiments B1 to B9 wherein from about 35% to about 80%, from about 35% to about 75%, from about 35% to about 65%, from about 40% to about 80%, from about 40% to about 75%, or from about 40% to about 70% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 50 nm.

Embodiment B12 is the shaped porous carbon product of any one of embodiments B1 to B11 wherein at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 100 nm.

Embodiment B13 is the shaped porous carbon product of any one of embodiments B1 to B11 wherein from about 50% to about 95%, from about 50% to about 90%, from about 50% to about 80%, from about 60% to about 95%, from about 60% to about 90%, from about 60% to about 80%, from about 70% to about 95%, from about 70% to about 90%, from about 70% to about 80%, from about 80% to about 95%, or from about 80% to about 90% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter of from about 10 nm to about 100 nm.

Embodiment B14 is the shaped porous carbon product of any one of embodiments B1 to B13 wherein no more than about 10%, no more than about 5%, or no more than about 1% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter less than 3 nm.

Embodiment B15 is the shaped porous carbon product of any one of embodiments B1 to B13 wherein from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.1% to about 1%, from about 1% to about 10%, or from about 1% to about 5% of the pore volume of the shaped porous carbon product, as measured by the BJH process on the basis of pores having a diameter from 1.7 nm to 100 nm, is attributable to pores having a mean pore diameter less than 3 nm.

Embodiment B16 is the shaped porous carbon product of any one of embodiments B1 to B15 wherein the shaped porous carbon product has a pore size distribution such that the peak of the distribution is at a diameter greater than about 5 nm, greater than about 7.5 nm, greater than about 10 nm, greater than about 12.5 nm, greater than about 15 nm, or greater than about 20 nm.

Embodiment B17 is the shaped porous carbon product of any one of embodiments B1 to B15 wherein the shaped porous carbon product has a pore size distribution such that the peak of the distribution is at a diameter less than about 100 nm, less than about 90 nm, less than about 80 nm, or less than about 70 nm.

Embodiment B18 is the shaped porous carbon product of any one of embodiments B1 to B17 wherein the shaped porous carbon product has a radial piece crush strength from about 4.4 N/mm (1 lb/mm) to about 88 N/mm (20 lbs/mm), from about 4.4 N/mm (1 lb/mm) to about 66 N/mm (15 lbs/mm), from about 8.8 N/mm (2 lb/mm) to about 44 N/mm (10 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 15 N/mm (3.4 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 88 N/mm (20 lbs/mm), from about 17 N/mm (3.8 lbs/mm) to about 44 N/mm (10 lbs/mm), from about 20 N/mm (4.5 lbs/mm) to about 88 N/mm (20 lbs/mm), or from about 20 N/mm (4.5 lbs/mm) to about 44 N/mm (10 lbs/mm).

Embodiment B19 is the shaped porous carbon product of any one of embodiments B1 to B18 wherein the shaped porous carbon product has a mechanical piece crush strength greater than about 22 N (5 lbs), greater than about 36 N (8 lbs), or greater than about 44 N (10 lbs).

Embodiment B20 is the shaped porous carbon product of any one of embodiments B1 to B18 wherein the shaped porous carbon product has a mechanical piece crush strength from about 22 N (5 lbs) to about 88 N (20 lbs), from about 22 N (5 lbs) to about 66 N (15 lbs), or from about 33 N (7.5 lbs) to about 66 N (15 lbs).

Embodiment B21 is the shaped porous carbon product of any one of embodiments B1 to B20 wherein the shaped porous carbon product has a mean diameter of at least about 50 μm, at least about 500 μm, at least about 1,000 μm, or at least about 10,000 μm.

Embodiment B22 is the shaped porous carbon product of any one of embodiments B1 to B21 wherein the shaped porous carbon product has a carbonaceous material content of at least about 35 wt. %, at least about 40 wt. %, at least about 45 wt. %, at least about 50 wt. %, at least about 55 wt. %, at least about 60 wt. %, at least about 65 wt. %, or at least about 70 wt. %.

Embodiment B23 is the shaped porous carbon product of any one of embodiments B1 to B21 wherein the shaped porous carbon product has a carbonaceous material content from about 35 wt. % to about 80 wt. %, from about 35 wt. % to about 75 wt. %, from about 40 wt. % to about 80 wt. %, or from about 40 wt. % to about 75 wt. %.

Embodiment B24 is the shaped porous carbon product of any one of embodiments B1 to B23 wherein the shaped porous carbon product has a carbonized binder content from about 10 wt. % to about 50 wt. %, from about 20 wt. % to about 50 wt. %, from about 25 wt. % to about 40 wt. %, or from about 25 wt. % to about 35 wt. %.

Embodiment C1 is a shaped porous carbon product prepared by a process according to any one of embodiments A1 to A81.

Embodiment D1 is a process of preparing a catalyst composition, the process comprising preparing a shaped porous carbon product according to the process of any one of embodiments A1 to A81 and depositing a catalytically active component or precursor thereof on the shaped porous carbon product.

Embodiment D2 is a process of preparing a catalyst composition, the process comprising depositing a catalytically active component or precursor thereof on the shaped porous carbon product of any one of embodiments B1 to B24.

Embodiment D3 is the process of embodiment D1 or D2 wherein the catalytically active component or precursor thereof comprises a metal.

Embodiment D4 is the process of embodiment D3 wherein the metal comprises at least one d-block metal.

Embodiment D5 is the process of embodiment D3 wherein the metal comprises at least one metal selected from groups VI, V, VI, VII, VIII, IX, X, XI, XII, and XIII.

Embodiment D6 is the process of embodiment D3 wherein the metal comprises a noble metal.

Embodiment D7 is the process of embodiment D3 wherein the metal comprises a non-noble metal.

Embodiment D8 is the process of embodiment D3 wherein the metal is selected from the group consisting of cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof.

Embodiment D9 is the process of any one of embodiments D3 to D8 wherein the metal constitutes from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10% of the total weight of the catalyst composition.

Embodiment E1 is a catalyst composition comprising a shaped porous carbon product as a catalyst support and a catalytically active component or precursor thereof, wherein, the shaped porous carbon product is prepared in accordance with any one of embodiments A1 to A81.

Embodiment E2 is a catalyst composition comprising a shaped porous carbon product of any one of embodiments B1 to B24 as a catalyst support and a catalytically active component or precursor thereof.

Embodiment E3 is the process of embodiment E1 or E2 wherein the catalytically active component or precursor thereof comprises a metal.

Embodiment E4 is the process of embodiment E3 wherein the metal comprises at least one d-block metal.

Embodiment E5 is the process of embodiment E3 wherein the metal comprises at least one metal selected from groups VI, V, VI, VII, VIII, IX, X, XI, XII, and XIII.

Embodiment E6 is the process of embodiment E3 wherein the metal comprises a noble metal.

Embodiment E7 is the process of embodiment E3 wherein the metal comprises a non-noble metal.

Embodiment E8 is the process of embodiment E3 wherein the metal is selected from the group consisting of cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof.

Embodiment E9 is the process of any one of embodiments E3 to E8 wherein the metal constitutes from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10% of the total weight of the catalyst composition.

The following non-limiting examples are provided to further illustrate the present invention.

EXAMPLES

Surface areas were determined from nitrogen adsorption data using the BET method as described in S. Brunauer, P. H. Emmett, E. Teller, J. Am. Chem. Soc. 1938, 60, 309-331, and ASTM D3663-03(2008) Standard Test Method for Surface Area of Catalysts and Catalyst Carriers. Mean pore diameters and pore volumes were determined in accordance with the procedures described in E. P. Barrett, L. G. Joyner, P. P. Halenda, J. Am. Chem. Soc. 1951, 73, 373-380, and ASTM D4222-03(2008) Standard Test Method for Determination of Nitrogen Adsorption and Desorption Isotherms of Catalysts and Catalyst Carriers by Static Volumetric Measurements.

Mercury Porosimetry measurements were conducted using an AutoPore V Mercury Porosimeter from Micromeritics Instrument Corporation. A suitable amount of carbon extrudates were loaded into an appropriate penetrometer and mercury intrusion was measured in two sequential stages: low pressure analysis (0 to 50 psia) followed by high pressure analysis (50 to 33,000 psia). A total of 712 data points were collected across the whole range of pressure with a contact angle of 154.0°.

Radial piece crush strength measurements were conducted according to ASTM D6175-03(2013) Standard Test Method for Radial Crush Strength of Extruded Catalyst and Catalyst Carrier Particles using a press apparatus equipped with a Dillon GS100 Digital Force Gauge. Mean radial piece crush strength is the average value of independent measurements of at least 10 different extrudate pellets.

Single piece crush strength were conducted according to ASTM D4179-03(2013) Standard Test Method for Single Pellet Crush Strength of Formed Catalysts and Catalyst Carriers using a press apparatus equipped with a Dillon GS100 Digital Force Gauge. Single piece crush strength is the average value of independent measurements of at least 10 different extrudate pellets.

Example 1 Preparation of Carbon Black Extrudates

36.4 g of carbon black powder (Cabot VULCAN XC72, 224 m²/g) was added in multiple portions to a heated (overnight at 80° C.) aqueous solution (136.5 g) containing 24.3 wt. % Cerelose Dextrose from Ingredion and 4.7 wt. % hydroxyethylcellulose from Sigma-Aldrich (SKU 54290, viscosity 80-125 mPa·s (cP), 2% in H₂O (20° C.)). The mixture was stirred well using a spatula to produce a paste. This paste was loaded into a syringe and the material was extrudated into spaghetti-like strings with about 1.5 mm diameter. After drying in a 70° C. oven for 5 hours under a dry air purge, these strings were cut into small pieces about 1.0 cm long. Then they were treated at 350° C. for 2 hours with 10° C./min temperature ramp rate under continuous N₂ flow to carbonize the binder and produce a carbon black extrudate.

The properties of the resultant extrudate are show in Table 1.

TABLE 1 BET Surface Mean Pore Pore Volume Area (m²/g) Diameter (Å) (cm³/g) Extrudate of 110 110 0.15 Cabot VULCAN XC72

Example 2 Characterization of Component Carbon Black Powder

The properties of various carbon black powders utilized in the shaped porous carbon black products were characterized.

A. Physical Properties of Carbon Black Powders

The BET specific surface area, specific mean pore diameter and specific pore volume of these carbon black powder starting materials were determined using the methods described above, and are provided in Table 2.

TABLE 2 BET Surface Mean Pore Pore Area Diameter Volume Carbon Black (m²/g) (Å) (cm³/g) Asbury 5365R 34 143 0.11 Asbury 5353R 35 186 0.14 Asbury 5345R 35 207 0.11 Timcal ENSACO 64 140 0.24 250G Asbury 5348R 65 220 0.31 Asbury 5358R 67 213 0.34 Asbury 5346R 80 145 0.28 Cabot MONARCH 102 138 0.30 570 Orion HP 160 158 208 0.87 Cabot MONARCH 181 121 0.38 700 Cabot VULCAN 224 161 0.43 XC72

B. Catalytic Performance

The carbon black powders were evaluated as catalyst support material in an oxidation reaction for converting glucose to glucaric acid as described below.

(i) Oxidation of Glucose to Glucaric Acid (Protocol 1)

Suitably concentrated aqueous solutions of Me₄NAuO₂ and PtO(NO₃) were added together to carbon black powders by incipient wetness impregnation and agitated to impregnate the supports. The samples were dried in an oven at 70° C. overnight, and reduced at 350° C. under a forming gas (5% H₂ and 95% N₂) atmosphere for 4 hours with 2° C./min temperature ramp rate to produce catalysts with a composition of 2.0 wt. % Au and 2.0 wt. % Pt. By using other carbon black supports, Au and Pt precursors, and adjusting amount of Au and Pt in solution, different catalysts with various Au and Pt loadings on a variety of commercial carbon black powders or particles from extrudates were prepared in a similar manner.

These catalysts were tested for glucose oxidation using the following testing protocol. Catalyst (8 mg) was weighed into a glass vial insert followed by addition of an aqueous glucose solution (250 μl of 0.55 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with oxygen and pressurized to 618 kPa (75 psig) at room temperature. Reactor was heated to 110° C. and maintained at the respective temperature for 2 hours while vials were shaken. After that, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was then slowly released. The glass vial insert was removed from the reactor and centrifuged. The solution was diluted with deionized water and analyzed by ion chromatography to determine the yield of glucaric acid. Selectivity is defined as 100%×(glucaric acid)/(sum of glucaric acid and all off-pathway species). Off-pathway species that cannot be converted to glucaric acid include 2-ketogluconic acid, 3-ketogluconic acid, 4-ketogluconic acid, 5-ketogluconic acid, trihydroxyglutaric acid, tartaric acid, tartronic acid and oxalic acid. On-pathway species include glucose, gluconic acid, guluronic acid and glucuronic acid. On-pathway species are not used in the selectivity calculation because these intermediates can be partially converted to glucaric acid and are not considered off-pathway. Results are presented in Table 3.

TABLE 3 Glucaric Surface Mean Pore Pore Acid Selec- Area Diameter Volume Yield tivity Support (m²/g) (Å) (cm³/g) (%) (%) Asbury 5302 211 99 0.29 33 76 Asbury 5303 219 79 0.23 38 77 Asbury 5368 303 102 0.54 34 78 Asbury 5379 271 163 0.83 33 75

(ii) Oxidation of Glucose to Glucaric Acid (Protocol 2)

Suitably concentrated aqueous solutions of K₂Pt(OH)₆ and CsAuO₂ were added together to carbon black powders by incipient wetness impregnation and agitated to impregnate the supports. The samples were dried in an oven at 40° C. overnight, and reduced at 250° C. under a forming gas (5% H₂ and 95% N₂) atmosphere for 3 hours with 5° C./min temperature ramp rate. The final catalysts were washed with deionized water and finally dried at 40° C. to produce catalysts with a composition of 2.44 wt. % Pt and 2.38 wt. % Au. By using other carbon black supports, Au and Pt precursors, and adjusting amount of Au and Pt in solution, different catalysts with various Au and Pt loadings on a variety of commercial carbon black powders or particles from extrudates were prepared in a similar manner.

These catalysts were tested for glucose oxidation using the following testing protocol. Catalyst (10 mg) was weighed into a glass vial insert followed by addition of an aqueous glucose solution (250 μl of 0.55 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with oxygen and pressurized to 618 kPa (75 psig) at room temperature. Reactor was heated to 90° C. and maintained at the respective temperature for 5 hours while vials were shaken. After that, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was then slowly released. The glass vial insert was removed from the reactor and centrifuged. The solution was diluted with deionized water and analyzed by ion chromatography to determine the yield of glucaric acid and the selectivity as defined herein. Results are presented in Table 4.

TABLE 4 Glucaric Surface Mean Pore Pore Acid Selec- Area Diameter Volume Yield tivity Support (m²/g) (Å) (cm³/g) (%) (%) Asbury 5365R 34 143 0.11 42 78 Asbury 5353R 35 186 0.14 38 82 Asbury 5345R 35 207 0.11 44 76 Timcal ENSACO 64 140 0.24 60 83 250G Asbury 5348R 65 220 0.31 54 78 Asbury 5358R 67 213 0.34 52 77 Asbury 5346R 80 145 0.28 48 75 Cabot MONARCH 102 138 0.3 37 75 570 Orion HP 160 158 208 0.87 35 77 Cabot MONARCH 181 121 0.38 42 77 700 Cabot VULCAN 224 161 0.43 46 77 XC72

Example 3 Preparation of Shaped Porous Carbon Black Product Using a Variety of Carbon Black Powders and Binders

By using other carbon black powders and carbohydrate binders, different carbon black extrudates were prepared as described in Example 1. Other carbon black powders included, but were not limited to, Orion carbon HI-BLACK 40B2, Orion HI-BLACK 50LB, Orion Hi-BLACK SOL, Orion HP-160, Orion Carbon HI-BLACK N330, Timcal ENSACO 150 G, Timcal ENSACO 250 G, Timcal ENSACO 260G, Timcal ENSACO 250P, Cabot VULCAN XC72R, Cabot MONARCH 120, Cabot MONARCH 280, Cabot MONARCH 570, Cabot MONARCH 700, Asbury 5365R, Asbury 5353R, Asbury 5345R, Asbury 5352, Asbury 5374, Asbury 5348R, Asbury 5358R, Sid Richardson SC159, Sid Richardson SR155. Other carbohydrate binders included, but were not limited to, Cargill Clearbrew 60/44 IX (80% Carbohydrate), Casco Lab Fructose 90 (70% Carbohydrate) and Molasses (80% Carbohydrate). Formulations with these variations yielded illustrative examples of the shaped carbon product of the present invention. The properties of some of these embodiments are described in more detail below.

Example 4 Crush Testing of Carbon Black Extrudates

Extrudate pellets (Nos. 1-8 below), having an approximately 1.5 mm diameter, were prepared according to the method described in Example 1 except that the final pyrolysis times and temperatures were varied as listed in Table 5 in the extrudate description column. After the pyrolysis step the extrudates were cut to the sizes ranging from 2-6 mm in length. The percentage of carbonized binder (after pyrolysis) present in the shaped carbon product was determined by mass balance [i.e., [(Weight_(Shaped Carbon Product)−Weight_(Carbon Black (in formulation))/Weight_(Shaped Carbon Product))×100]. Total binder content after pyrolysis (i.e., total carbonized binder) varied from 15-50 wt. %.

Additional extrudate pellets (Nos. 9-11 below) were prepared accordingly to the following procedure. Approximately 24.0 g of carbon black powder (Timcal ENSACO 250G, 65 m²/g) was added in multiple portions to an aqueous solution (100.0 g) containing 25.0 wt. % Cerelose Dextrose from Ingredion. The mixture was stirred well using a spatula to produce a paste. This paste was loaded into a syringe and the material was extrudated into spaghetti-like strings with a 1.5 mm diameter. After drying in a 100° C. oven for 3 hours under a dry air purge, these strings were cut into smaller pieces (2-6 mm lengths). Then they were treated at one of the following conditions to produce carbon black extrudates: (1) 250° C. for 3 hours with 10° C./min temperature ramp rate under continuous N₂ flow; (2) 800° C. for 4 hours with 10° C./min temperature ramp rate under continuous N₂ flow; (3) 200° C. for 3 hours with 10° C./min temperature ramp rate in air. Binder content varied from 15 to 50 wt. %. Table 5 presents the crush strength data for the extrudates prepared.

TABLE 5 Mean Mechan- Mean Mean ical Radial Radial Carbon- Piece Piece Piece ized Crush Crush Crush Binder Strength Strength Strength Content No. Extrudate Description (lb) (N/mm) (lb/mm) (wt. %) 1 Cabot MONARCH 120 8.7 9.2 2.1 15 (Glucose + Hydroxyethylcellulose binder, 350° C./2 h/N₂) 2 Cabot MONARCH 280 5.4 7.7 1.7 23 (Glucose + Hydroxyethylcellulose binder, 800° C./2 h/N₂) 3 Cabot MONARCH 700 12.3 12.3 2.8 31 (Glucose + Hydroxyethylcellulose binder, 350° C./2 h/N₂) 4 Cabot MONARCH 700 6.3 6.3 1.4 34 (Glucose + Hydroxyethylcellulose binder, 500° C./2 h/N₂) 5 Cabot MONARCH 700 18.7 18.5 4.2 31 (Glucose + Hydroxyethylcellulose binder, 800° C./2 h/N₂) 6 Cabot VULCAN XC72 5.6 5.6 1.2 30 (Glucose + Hydroxyethylcellulose binder, 800° C./2 h/N₂) 7 Cabot VULCAN XC72R 7.8 7.8 1.8 38 (Glucose + Hydroxyethylcellulose binder, 350° C./2 h/N₂) 8 Timcal ENSACO 250P 8.6 8.6 1.9 50 (Glucose + Hydroxyethylcellulose binder, 350° C./2 h/N₂) 9 Timcal ENSACO 250G 10.9 10.9 2.5 32 (Glucose binder, 800° C./4 h/N₂) 10 Timcal ENSACO 250G 6.2 6.2 1.4 29 (Glucose binder, 200° C./3 h/Air) 11 Timcal ENSACO 250G 3.8 3.8 0.9 29 (Glucose binder, 250° C./3 h/N₂)

Example 5 Preparation of Catalyst Compositions

The Cabot VULCAN XC72 carbon black extrudates prepared in Example 1 were further cut into small pieces of about 0.5 cm long for testing. An aqueous solution (13 ml) containing 0.17 g Au in the form of Me₄NAuO₂ and 0.26 g Pt in the form of PtO(NO₃) was mixed with 21.5 g of these extrudates. The mixture was agitated to impregnate the carbon black support and was dried in a 60° C. oven overnight under a dry air purge. The sample was then reduced at 350° C. under forming gas (5% H₂ and 95% N₂) atmosphere for 4 hours with 2° C./min temperature ramp rate. The final catalyst was composed of about 0.80 wt. % Au and 1.2 wt. % Pt.

By using other carbon black extrudates prepared from the method described above, a series of Pt—Au extrudate catalysts spanning ranges in Au and Pt loadings, Pt/Au ratios and metal distributions (e.g., eggshell, uniform, subsurface bands) could be prepared.

The cross section of a sample of the catalyst extrudate prepared with Cabot VULCAN XC72 carbon black was analyzed using scanning electron microscopy. FIG. 1 provides an image of this analysis. The image shows that platinum and gold metal was deposited on the external surface of the carbon black extrudate forming a shell coating the outer surfaces the carbon black extrudate. FIG. 2 provides a magnified view of one of catalyst extrudate cross-sections with measurements of the diameter of the carbon black extrudate (i.e., 1.14 mm) and thickness of the platinum and gold shell (average of about 100 μm) on the carbon black extrudate outer surface.

Example 6 Testing of Au/Pt Carbon Black Extrudate Catalysts (using Cabot MONARCH 700) in a Fixed-Bed Reactor for the Oxidation of Glucose to Glucaric Acid

Extrudates based on carbon black Cabot MONARCH 700 with glucose and hydroxyethylcellulose binder and subsequent catalyst with 0.80 wt. % Au and 1.20 wt. % Pt were prepared by mixing carbon black Cabot MONARCH 700 (42.0 g) and a binder solution (145.8 g prepared by heating a solution containing 3.4 wt. % hydroxyethylcellulose and 28.6 wt. % glucose at 80° C. overnight)), The resultant paste was loaded into a syringe and the material was extrudated into spaghetti-like strings with a 1.5 mm diameter. After drying in a 100° C. oven for 3 hours under a dry air purge, these strings were cut into smaller pieces (2-6 mm lengths) and pyrolyzed at 350° C. for 2 hours under a nitrogen atmosphere. The final carbonized binder content in carbon extrudates was 31 wt. %. The catalyst was then prepared using the method described in Example 5. Oxidation of glucose reactions were conducted in a 12.7 mm (0.5-inch) OD by 83 cm long 316 stainless steel tube with co-current down-flow of gas and liquid. Catalyst beds were vibration packed with 1.0 mm glass beads at the top to approximately 8 cm depth, followed by catalyst (67 cm bed depth containing 20.0 g, 0.80 wt. % Au+1.2 wt. % Pt on Cabot MONARCH 700 carbon black pellets with a length of 0.5 cm and diameter of 1.5 mm prepared using the method described in Example 3), then 1.0 mm glass beads at the bottom to approximately 8 cm depth. Quartz wool plugs separated the catalyst bed from the glass beads.

The packed reactor tube was clamped in an aluminum block heater equipped with PID controller. Gas (compressed dry air) and liquid flows were regulated by mass flow controller and HPLC pump, respectively. A back pressure regulator controlled reactor pressure as indicated in Table 6. The catalyst was tested for approximately 350 hours of time on stream (TOS).

Table 6 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. The catalyst productivity in Table 6 is 35 gram (glucaric acid) per gram (Pt+Au)⁻¹ hr⁻¹ or 0.70 gram (glucaric acid) per gram (catalyst)⁻¹ hr⁻¹.

TABLE 6 Reactor Gas block Glucose feed Reactor Liquid flowrate/ temperature/ concentration/ pressure/ flowrate/ mL min⁻¹ Glucose Glucaric ° C. wt. % psi mL min⁻¹ (STP) conversion/% acid yield/% Selectivity/% 130 20 750 2.00 768 >99 50 86

BET surface area measurements and BJM pore volume distribution measurements were made on the following carbon black and extrudate samples:

Sample 1: MONARCH 700 carbon black material.

Sample 2: Fresh MONARCH 700 extrudate prepared in accordance with this Example.

Sample 3: MONARCH 700 extrudate of Example 4 following 350 hours on stream in a fixed bed reactor (described in Example 6).

Sample 4: An aqueous solution (915.0 g) containing 4.0 wt. % hydroxyethylcellulose (Sigma-Aldrich, SKU 54290, viscosity 80-125 mPa·s (cP), 2% in H₂O (20° C.)) and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2255 wt. % Glucose content) was prepared by stirring 36.6 g hydroxyethylcellulose and 561.7 g Dextrose Monohydrate in 316.7 ml D.I. water at 80° C. for 16 hours. After cooling to ambient temperature, this viscous solution was added to 400.0 g carbon black powder (Cabot MONARCH 700) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then loaded into a 2.54 cm (1-inch) Bonnot BB Gun Extruder and extrudated into spaghetti like strings with ca. 1.5 mm diameter at cross section. These strings were dried under a dry air purge in a 120° C. oven for 16 hours and then pyrolyzed at 800° C. for 2 hours with 5° C./min ramp rate under a nitrogen purge. The final carbonized binder content was to be 36 wt. %.

Sample 5: Prepared as described by Example 9.

Sample 6: Prepared as described by Example 12.

Sample 7: An aqueous solution (166.0 g) containing 4.0 wt. % hydroxyethylcellulose (Sigma-Aldrich, SKU 54290, viscosity 80-125 mPa·s (cP), 2% in H₂O (20° C.)) and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2255 wt. % Glucose content) was prepared by stirring 6.64 g hydroxyethylcellulose and 84.8 g Dextrose Monohydrate in 74.6 ml D.I. water at 80° C. for 16 hours. After cooling to ambient temperature, this viscous solution was added to 60.0 g carbon powder (Asbury 5368) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then loaded into a 2.54 cm (1 inch) Bonnot BB Gun Extruder and extrudated into spaghetti like strings with ca. 1.5 mm diameter at cross section. These strings were dried under a dry air purge in a 120° C. oven for 16 hours and then pyrolyzed at 800° C. for 2 hours with 5° C./min ramp rate under a nitrogen purge. The final carbonized binder content was 40 wt. %.

Sample 8: Commercially available activated carbon extrudate Sud Chemie G32H-N-75.

Sample 9: Commercially available activated carbon extrudate Donau Supersorbon K4-35.

The results are presented in Table 7.

TABLE 7 Pores Pores Pores between between 10 BET Mean BJH <3 nm 10 and 50 nm and 100 nm Carbonized Surface Pore Pore (% of (% of (% of BJH Binder Area Diameter Volume BJH pore BJH pore pore Content Sample (m²/g) (nm) (cm³/g) volume) volume) volume) (wt %) Sample 1 180 12 0.38 5 40 75  0 Sample 2 178 11 0.29 7 45 75 36 Sample 3 98 18 0.31 3 50 90 36 Sample 4 182 13 0.36 4 55 80 36 Sample 5 194 11 0.29 6 45 75 36 Sample 5 234 10 0.29 7 45 70 36 Sample 6 218 12 0.33 5 60 80 40 Sample 8 1164 3.4 0.63 40 <15 15 ** Sample 9 1019 2.7 0.31 65 5 7 **

FIG. 3 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a raw MONARCH 700 carbon black material. FIG. 4 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a fresh catalyst prepared from a carbon black extrudate using MONARCH 700 and a glucose/hydroxyethylcellulose binder. FIG. 5 presents a plot of the cumulative pore volume (%) as a function of pore diameter for the catalyst extrudate of FIG. 2 following 350 hours of use in a fixed bed reactor for the oxidation of glucose to glucaric acid. FIG. 6 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using MONARCH 700 carbon black and a glucose/hydroxyethyl cellulose binder. FIG. 7 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Sid Richardson SC 159 carbon black and a glucose/hydroxyethyl cellulose binder. FIG. 8 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Sid Richardson SC 159 carbon black and a glucose/hydroxyethyl cellulose binder prepared in accordance with Example 12. FIG. 9 presents a plot of the cumulative pore volume (%) as a function of pore diameter for an extrudate using Asbury 5368 carbon black and a glucose/hydroxyethyl cellulose binder. FIG. 10 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a commercially available activated carbon extrudate of Sud Chemie G32H-N-75. FIG. 11 presents a plot of the cumulative pore volume (%) as a function of pore diameter for a commercially available activated carbon extrudate of Donau Supersorbon K4-35.

FIG. 12 presents the pore size distribution for an extrudate using Sid Richardson SC159 carbon black and a glucose/hydroxyethyl cellulose binder measured by mercury porosimetry. These plots show that the micropore contribution to pore volume for carbon black extrudate catalysts (fresh and after use) is very low. In particular the plots show that the micropore contribution (pores <3 nm) is less than 10% of the BJH pore volume. In some instances the micropore contribution (pores <3 nm) is less than 6% of the BJH pore volume, and in some instances the micropore contribution (pores <3 nm) is less than 4% of the BJH pore volume. In contrast, the micropore contribution to pore volume for an activated carbon extrudate catalyst is exceedingly high at 40%. Also, the plots show that the contribution to pore volume from pores having a mean diameter from about 10 nm to 50 nm for the carbon black catalysts was about 40% or higher. On the other hand, the contribution to pore volume from pores having a mean diameter from about 10 nm to 50 nm for the activated carbon catalyst was less than 15%. The plots show that the contribution to pore volume from pores having a mean diameter from about 10 nm to 100 nm for the carbon black catalysts was about 70% or higher. On the other hand, the contribution to pore volume from pores having a mean diameter from about 10 nm to 100 nm for the activated carbon catalyst was 15% or less.

Example 7 Testing of Au/Pt Carbon Black Extrudate Catalysts (using Cabot VULCAN XC72) in a Fixed-Bed Reactor for the Oxidation of Glucose to Glucaric Acid

Extrudates based on carbon black Cabot VULCAN XC72 and subsequent catalyst with 0.80 wt. % Au and 1.20 wt. % Pt were prepared by mixing carbon black Cabot VULCAN XC72 (36.4 g) and a binder solution (136.5 g prepared by heating a solution containing 3.7 wt. % hydroxyethylcellulose and 24.4 wt. % glucose at 80° C. overnight). The resultant paste was loaded into a syringe and the material was extrudated into spaghetti-like strings with a 1.5 mm diameter followed by drying at 120° C. for 4 hours in air, and pyrolysis at 350° C. for 2 hours under a nitrogen atmosphere. The final binder content in pyrolyzed carbon extrudates was 30 wt. %. The catalysts were prepared using the method described in Example 3. The catalyst was tested in the same 12.7 mm (0.5-inch) OD fixed-bed reactor as in Example 6. Table 8 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. The catalyst productivity in Table 8 is 36 gram (glucaric acid) per gram (Pt+Au)⁻¹ hr⁻¹ or 0.72 gram (glucaric acid) per gram (catalyst)⁻¹ hr⁻¹.

TABLE 8 Reactor Gas block Glucose feed Reactor Liquid flowrate/ temperature/ concentration/ pressure/ flowrate/ mL min⁻¹ Glucose Glucaric ° C. wt. % psi mL min⁻¹ (STP) conversion/% acid yield/% Selectivity/% 130 20 750 2.00 768 >99 52 87

Example 8 Oxidation of Glucose to Glucaric Acid-Activated Carbons with High Surface Areas (Comparative)

The same synthesis procedure described in Example 6 was used to prepare Pt—Au catalysts supported on high surface area activated carbon. The activated carbon extrudates were crushed and sieved to <90 μm prior to the catalyst preparation and screening. The catalysts were screened in the same reactor under the same conditions described in Example 2(B)(ii). As shown in Table 9, the high surface area activated carbon carriers were found to exhibit lower activity and lower selectivity (as defined herein).

TABLE 9 Glucaric Surface Mean Pore Pore Acid Selec- Area Diameter Volume Yield tivity Support (m²/g) (Å) (cm³/g) (%) (%) Donau Supersorbon 1019 27 0.31 22 66 K4-35 Donau Supersorbon 1050 39 0.71 18 68 SX30 Norit RX3 Extra 1239 37 0.23 20 70

Example 9 Preparation of Carbon Black Extrudate Catalysts Attrition and Abrasion Testing

An aqueous solution (113 g) containing 4.0 wt. % hydroxyethylcellulose (Sigma-Aldrich, SKU 54290, viscosity 80-125 mPa·s (cP), 2% in H₂O (20° C.)) and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2255 wt. % Glucose content) was prepared by stirring 4.5 g hydroxyethylcellulose and 69.4 g Dextrose Monohydrate in 39.1 ml D.I. water at 80° C. overnight. After cooling to room temperature, this viscous solution was added to 50 g carbon black powder (Sid Richardson SC159, 231 m²/g) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then loaded into a 2.54 cm (1 inch) Bonnot BB Gun Extruder and extrudated into spaghetti like strings with ca. 1.5 mm diameter at cross section. These strings were dried under a dry air purge in a 120° C. oven overnight and then pyrolyzed at 800° C. for 4 hours with 5° C./min ramp rate under a nitrogen purge. The extruded and pyrolyzed samples were cut into small pieces of about 0.5 cm long for testing.

The properties of the resultant extrudate are show in Table 10. BET and crush strength measurements performed as described in the current disclosure.

TABLE 10 BET Single Piece Mean Surface Mean Pore Pore Crush Radial Piece Area Diameter Volume Strength Crush Strength (m²/g) (Å) (cm³/g) (N) (N/mm) 194 112 0.29 90 30

Extrudates prepared in accordance with this example were tested for the determination of attrition index (ASTM D4058-96) and abrasion loss according to the procedure described below.

Measurement of Attrition Index.

The ASTM attrition index (ATTR) is a measurement of the resistance of a catalyst or extrudate particle to attrition wear, due to the repeated striking of the particle against hard surfaces within the specified test drum. The diameter and length of the drum is similar to that described in ASTM D4058, with a rolling apparatus capable of delivering 55 to 65 RPM of rotation to the test drum. The percentage of the original sample that remains on a 20-mesh sieve is called the “Percent Retained” result of the test. The results of the test can be used, on a relative basis, as a measure of fines production during the handling, transportation, and use of the catalyst or extrudate material. A percent retained result of >97% is desirable for an industrial application.

Approximately 100 g of the extrudate material prepared in Example 9 above was transferred to the test drum which was fastened and transferred to the rolling apparatus and rolled at 55 to 65 RPM for 35 minutes. The weight percent retained after the test was 99.7%.

Measurement of Abrasion Loss.

The abrasion loss (ABL) is an alternate measurement of the resistance of a catalyst or extrudate particle to wear, due to the intense horizontal agitation of the particles within the confines of a 30-mesh sieve. The results of this procedure can be used, on a relative basis, as a measure of fines production during the handling, transportation, and use of the catalyst or adsorbent material. An abrasion loss of <2 wt. % is desired for an industrial application. Approximately 100 g of the extrudate material prepared in example 9 above was first de-dusted on a 20-mesh sieve by gently moving the sieve side-to-side at least 20 times. The de-dusted sample was then transferred to the inside of a clean, 30-mesh sieve stacked above a clean sieve pan for the collection of fines. The complete sieve stack was then assembled onto a RO-Tap RX-29 sieve shaker, covered securely and shaken for 30 minutes. The fines generated were weighed to provide a sample abrasion loss of 0.016 wt. %.

Example 10 Testing of Au/Pt Carbon Black Extrudate Catalysts of Example 9 in a Fixed-Bed Reactor for the Oxidation of Glucose to Glucaric Acid

The carbon black extrudates prepared from the method described in Example 9 were further cut into small pieces of about 0.5 cm long for testing. To 27.0 g of these extrudates, an aqueous solution (8.0 ml) containing 0.16 g Au in the form of Me₄NAuO₂ and 0.24 g Pt in the form of PtO(NO₃) was added. The mixture was agitated to impregnate the carbon black support and was dried in a 70° C. oven for 1 hour under a dry air purge. The sample was then reduced at 350° C. under forming gas (5% H₂ and 95% N₂) atmosphere for 4 hours with 2° C./min temperature ramp rate. The final catalyst was composed of ca. 0.60 wt. % Au and 0.90 wt. % Pt. By using other carbon black extrudates prepared from the methods described herein, a series of Pt—Au extrudate catalysts spanning ranges in Au and Pt loadings, Pt/Au ratios and metal distributions (e.g., eggshell, uniform, subsurface bands) can be prepared.

The glucose to glucaric acid oxidation reaction was conducted in a 1.27 cm (½ inch) OD by 83 cm long 316 stainless steel tube with co-current down-flow of gas and liquid. Catalyst beds were vibration packed with 1.0 mm glass beads at the top to approximately 10 cm depth, followed by catalyst (63 cm bed depth containing 27.4 g, 0.60 wt. % Au+0.90 wt. % Pt on Sid Richardson SC159 carbon black pellets with a length of 0.5 cm and diameter of 1.4 mm prepared using the method described, then 1.0 mm glass beads at the bottom to approximately 10 cm depth. Quartz wool plugs separated the catalyst bed from the glass beads.

The packed reactor tube was clamped in an aluminum block heater equipped with PID controller. Gas (compressed dry air) and liquid flows were regulated by mass flow controller and HPLC pump, respectively. A back pressure regulator controlled reactor pressure as indicated in Table 11. The catalyst was tested for ca. 920 hours on stream and showed stable performance. Table 11 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. The catalyst productivity in Table 11 is 23 gram (glucaric acid) per gram (Pt+Au)⁻¹ hr⁻¹ or 0.35 gram (glucaric acid) per gram (catalyst)⁻¹ hr⁻¹.

TABLE 11 Gas Reactor block Glucose feed Reactor Liquid flowrate/ temperature/ concentration/ pressure/ flowrate/ mL min⁻¹ Glucose Glucaric ° C. wt. % psi mL min⁻¹ (STP) conversion/% acid yield/% Selectivity/ 125 20 750 2.00 512 >99 32 79

After 920 hours on stream the catalyst extrudate was removed and re-submitted for mechanical crush strength testing. The mean single piece crush strength and mean radial piece crush strength data were found be within experimental error unchanged from the data listed in Table 10, thereby illustrating that the extrudate catalyst prepared by the method described is productive, selective and stable under the continuous flow conditions described.

Example 11 Testing of Au/Pt Carbon Black Extrudate Catalysts (using Asbury 5368) in a Fixed-Bed Reactor for the Oxidation of Glucose to Glucaric Acid

Reactions were conducted in a 1.27 cm (½ inch) OD by 83 cm long 316 stainless steel tube with co-current down-flow of gas and liquid. Catalyst beds were vibration packed with 1.0 mm glass beads at the top to approximately 8 cm depth, followed by catalyst (73 cm bed depth containing 35.0 g, 0.50 wt. % Au+0.85 wt. % Pt on Asbury 5368 extruded pellets (as previously described for Sample 7 (Example 6) with a length of 0.5 cm and diameter of 1.4 mm prepared using the method described in previous example 9), then 1.0 mm glass beads at the bottom to approximately 8 cm depth. Quartz wool plugs separated the catalyst bed from the glass beads.

The packed reactor tube was clamped in an aluminum block heater equipped with PID controller. Gas (compressed dry air) and liquid flows were regulated by mass flow controller and HPLC pump, respectively. A back pressure regulator controlled reactor pressure as indicated in Table 12. The catalyst was tested for ca. 240 hours TOS and showed stable performance. Table 12 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. The catalyst productivity in Table 12 is 20 gram (glucaric acid) per gram (Pt+Au)⁻¹ hr⁻¹ or 0.27 gram (glucaric acid) per gram (catalyst)⁻¹ hr⁻¹.

TABLE 12 0.50 wt. % Au + 0.85 wt. % Pt/Asbury 5368 Extrudate (stable performance over 240 hours on stream) Gas Reactor block Glucose feed Reactor Liquid flowrate/ temperature/ concentration/ pressure/ flowrate/ mL min⁻¹ Glucose Glucaric ° C. wt. % psi mL min⁻¹ (STP) conversion/% acid yield/% Selectivity 125 20 750 2.00 512 >99 31 76

Example 12 Preparation of Carbon Black Extrudate Catalysts on Partially Oxidized Support

Sid Richardson SC159 carbon black extrudates prepared from the method described in example 9 were oxidized in air at 300° C. for 3 hours with 5° C./min ramp rate to give partially oxidized pellets. To 36.0 g of these partially oxidized extrudates, an aqueous solution (9.0 ml) containing 0.18 g Au in the form of Me4NAuO2 and 0.31 g Pt in the form of PtO(NO3) was added. The mixture was agitated to impregnate the carbon black support and was dried in a 60° C. oven overnight under a dry air purge. The sample was then reduced at 350° C. under forming gas (5% H2 and 95% N2) atmosphere for 4 hours with 2° C./min temperature ramp rate. The final catalyst was composed of ca. 0.50 wt. % Au and 0.85 wt. % Pt. By using other carbon black extrudates prepared from the method described herein, a series of Pt—Au extrudate catalysts spanning ranges in Au and Pt loadings, Pt/Au ratios and metal distributions (e.g., eggshell, uniform, subsurface bands) could be prepared. The glucose to glucaric acid oxidation reaction was conducted in a in a 1.27 cm (½ inch) OD by 83 cm long 316 stainless steel tube with co-current down-flow of gas and liquid. Catalyst beds were vibration packed with 1.0 mm glass beads at the top to approximately 6 cm depth, followed by catalyst (70.4 cm bed depth containing 34.5 g, 0.50 wt. % Au+0.85 wt. % Pt on partially oxidized Sid Richardson SC159 carbon black pellets with a length of 0.5 cm and diameter of 1.5 mm prepared using the method described in Example 2), then 1.0 mm glass beads at the bottom to approximately 6 cm depth. Quartz wool plugs separated the catalyst bed from the glass beads.

The packed reactor tube was clamped in an aluminum block heater equipped with PID controller. Gas (compressed dry air) and liquid flows were regulated by mass flow controller and HPLC pump, respectively. A back pressure regulator controlled reactor pressure as indicated in Table 13. The catalyst was tested for ca. 230 hours TOS and showed stable performance. Table 13 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. The catalyst productivity in Table 13 is 26 gram (glucaric acid) per gram (Pt+Au)⁻¹ hr⁻¹ or 0.36 gram (glucaric acid) per gram (catalyst)⁻¹ hr⁻¹.

TABLE 13 Gas Glucose feed Reactor Liquid flowrate/ Glucose Glucaric Reactor block concentration/ pressure/ flowrate/ mL min⁻¹ conversion/ acid yield/ temperature/° C. wt. % psi mL min⁻¹ (STP) % % 125 20 750 2.00 512 >99 42

Example 13 Preparation of Carbon Black Extrudates using a Poly(vinylalcohol) Porogen

An aqueous solution (490.0 g) containing 8.0 wt. % Mowiol 8-88 Poly(vinylalcohol) (Mw 67k, Sigma-Aldrich 81383) and 36.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2255 wt. % Glucose content) was prepared by stirring 39.2 g Mowiol 8-88 Poly(vinylalcohol) and 193.4 g Dextrose Monohydrate in 257.4 ml D.I. water at 70° C. overnight. After cooling to room temperature, this solution was added to 230 g carbon black powder (Sid Richardson SC159) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then loaded into a 2.54 cm (1 inch) Bonnot BB Gun Extruder and extrudated into spaghetti like strings with ca. 1.5 mm diameter at cross section. These strings were further dried in a 90° C. oven overnight under a dry air purge and then pyrolyzed at 600° C. for 4 hours with 5° C./min ramp rate in a nitrogen atmosphere. The final carbonized binder content was 24 wt. %. The resultant extrudate (3-5 mm in length) possessed a surface area of 149 m²/g, a pore volume of 0.35 cm³/g and a mean pore diameter of 16 nm. The mean radial piece crush strength of these pellets was measured to be 11.5 N/mm. The single piece crush strength was measured to be 42N.

Example 14 Testing of Au/Pt Activated Carbon Extrudate Catalysts (using Clariant Donau Supersorbon K4-35 Activated Carbon Extrudate) in a Fixed-Bed Reactor for the Oxidation of Glucose to Glucaric Acid

Catalyst based on activated carbon Clariant Supersorbon K 4-35 was prepared using the same method described in Example 7. Oxidation of glucose reactions were conducted using the same method described in Example 2(B)(ii). A catalyst bed depth of 73 cm containing 27.0 g, 0.53 wt. % Au+0.90 wt. % Pt on Clariant Supersorbon K 4-35 activated carbon pellets with a length of 0.5 cm and diameter of 1.4 mm was tested for approximately 40 hours of time on stream (TOS). Table 14 describes the fixed bed reactor conditions and resultant extrudate catalyst performance. After 40 hours on stream the glucaric acid yield and the catalyst productivity were determined to be lower than the shaped carbon black catalysts of the invention.

TABLE 14 Gas Glucose feed Reactor Liquid flowrate/ Reactor block concentration/ pressure/ flowrate/ mL min⁻¹ temperature/° C. wt. % psi mL min⁻¹ (STP) 125 20 750 2.00 512

Example 15 Preparation of Carbon Black Extrudates

An aqueous solution (915 g) containing 4.0 wt. % hydroxyethylcellulose (HEC) (Sigma-Aldrich, SKU 54290, viscosity 80-125 mPa·s (cP) at 2% in H₂O (20° C.)) and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) was prepared by stirring 36.6 g hydroxyethylcellulose and 561.7 g Dextrose Monohydrate in 316.7 ml D.I. water at approximately 80° C. for 2 hours. To this viscous solution was added 400.1 g of Sid Richardson SC159 carbon black powder, the mixture was then mixed for a further 10 minutes. The material was then loaded into a 2.54 cm (1-inch) diameter Bonnot “BB Gun” Catalyst Extruder, fitted with a 6.4 mm (0.25-inch) spacer and a die with 1.6 mm cylindrical holes, and extruded into spaghetti-like strings. The extrudate was dried in a 110° C. oven overnight, then pyrolyzed in a stationary lab furnace under a nitrogen purge at 800° C. for 4 hours (after ramping the temperature up at 5° C./minute to reach the target temperature). The pyrolyzed extrudate was analyzed for BET specific surface area, BJH specific pore volume, and bulk diameter, and radial piece crush strength. These results of these analyses are provided in Table 15.

TABLE 15 Properties of the pyrolyzed extrudate from Example 15 N₂ BET BJH N₂ Diameter at Radial Piece Surface Area Pore Volume cross section Crush Strength (m²/g) (cm³/g) (mm) (N/mm) 207 0.30 1.5 17

Example 16 Preparation of Carbon Black Extrudates

An aqueous solution (3813 g) containing 4.0 wt. % hydroxyethylcellulose (HEC) (Sigma-Aldrich, SKU 54290, viscosity 80-125 mPa·s (cP) at 2% in H₂O (20° C.)) and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) was prepared by stirring 153 g hydroxyethylcellulose and 2340 g Dextrose Monohydrate in 1320 ml D.I. water at approximately 80° C. for 3 hours. This viscous solution was added over 3.5 minutes to 1670 g of Sid Richardson SC159 carbon black powder in a 45.7 cm (18 inch) diameter Simpson mix-muller, the mixture was then mixed for a further 20 minutes in the mix-muller. The material was then loaded into a 5.7 cm (2.25-inch) diameter Bonnot Catalyst Extruder, fitted with 5 dies with 26 cylindrical holes each 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and no spacer, and extruded into spaghetti-like strings. 1515 g of the extrudate was dried in a 110° C. oven overnight, to produce 1240 g of dried extrudate. The product was then pyrolyzed in a stationary tube furnace under a nitrogen purge at 800° C. for 4 hours. The pyrolyzed extrudate was analyzed for BET specific surface area, BJH specific pore volume, and bulk diameter, and radial piece crush strength. These results of these analyses are provided in Table 16.

TABLE 16 Properties of the pyrolyzed extrudate from Example 16 N₂ BET BJH N₂ Diameter at Radial Piece Surface Area Pore Volume cross section Crush Strength (m²/g) (cm³/g) (mm) (N/mm) 169 0.23 1.4 13

Example 17 Preparation of Carbon Black Extrudates using Batch Pyrolysis in a Rotary Tube Furnace

An aqueous solution (3813 g) containing 4.0 wt. % of Dow Cellosize HEC QP 40 hydroxyethylcellulose (viscosity 80-125 mPa·s (cP) at 2% in H₂O (20° C.)), and 56.0 wt. % glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) was prepared by stirring 153 g hydroxyethylcellulose and 2340 g Dextrose Monohydrate in 1320 ml D.I. water at approximately 80° C. for 3 hours. This viscous solution was added over 3.5 minutes to 1670 g of Sid Richardson SC159 carbon black powder in a 45.7 cm (18 inch) diameter Simpson mix-muller, the mixture was then mixed for a further 20 minutes in the mix-muller. The material was then loaded into a 5.7 cm (2.25-inch) diameter Bonnot Catalyst Extruder, fitted with 5 dies with 26 cylindrical holes each 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and no spacer, and extruded into spaghetti-like strings. 3.9 kg of the extrudate was dried in a 110° C. oven overnight, to produce 2.93 kg of dried extrudate. This dried extrudate was then screened over an 18 mesh screen, and 2.91 kg of screened material were collected.

The mixing, extrusion, drying and screening procedure above was repeated 3 more times to generate a total of 4 batches of dried, screened extrudate, which were combined, as summarized in Table 17.

TABLE 17 Production of Carbon Black Extrudate in a 5.7 cm (2.25-inch) Extruder Mass of wet Mass of dried extrudate Mass of dried extrudate after collected extrudate screening Sample number (kg) (kg) (kg) 17.1 3.90 2.93 2.91 17.2 4.66 3.80 3.76 17.3 5.17 4.24 4.20 17.4 4.85 3.74 3.71 Combined Total 18.58 14.71 14.58

Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the dried extrudates had 17.7 wt. % moisture remaining.

650 g batches of the combined dried & screened extrudate of were then pyrolyzed in a rotary tube furnace under a nitrogen purge at 800° C. for 2 hours, each batch producing approximately 350 g of pyrolyzed product. For each batch, 650 g of the carbon black extrudates (prepared from Sid Richardson SC159 with glucose and hydroxyethylcellulose binders) were loaded into an MTI Corporation 12.7 cm (5-inch) Quartz Tube Three Zone Rotary Tube Furnace (OTF-1200X-5L-R-III-UL). The carbon black extrudates were pyrolyzed with the 12.7 cm (5-inch) quartz tube rotating at 4.0 rpm under a nitrogen atmosphere at 800° C. for 2 hours with the following temperature ramp: ambient temperature to 200° C. at 10° C./min, 200° C. to 600° C. at 5° C./min, 600° C. to 800° C. at 10° C./min, hold at 800° C. for 2 hours, then allowed to cool to ambient temperature, still under nitrogen purge. 350 g of pyrolyzed carbon black extrudates were recovered, for a simple “as is” mass-based yield of 53.8% yield (350 g/650 g).

Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the batch-pyrolyzed extrudates had 2.3 wt. % moisture, giving a dry-basis yield of 342 g. Since the dried extrudate starting material for the pyrolysis had a moisture level of 17.7 wt. %, the 650 g represents 535 g on a dry basis, and thus the yield of the pyrolysis on a dry basis is 63.9% (342 g/535 g). On a dry basis the dried extrudate starting material for the pyrolysis is 40 wt. % carbon black and 60 wt. % binder. Assuming the mass of carbon black is unchanged by the pyrolysis, then on a dry basis the pyrolyzed extrudates have a carbon black content of 62.6 wt. % and a carbonized binder content of 37.4 wt. %.

The properties of the batch-pyrolyzed extrudate are shown in Table 18. Other carbon black extrudates can be pyrolyzed at various temperatures in a similar manner, or using a continuously operating rotary kiln as described in the following Example.

TABLE 18 Properties of Carbon Black Extrudate Batch- Pyrolyzed in a Rotary Tube Furnace Radial Piece N₂ BET N₂ Mean BJH N₂ Crush Surface Area Pore Diameter Pore Volume Strength (m²/g) (Å) (cm³/g) (N/mm) Combined 191 100 0.29 15 Extrudates of Example 17 Batch- Pyrolyzed at 800° C. for 2 hours

Example 18 Preparation of Carbon Black Extrudates using Continuous Pyrolysis in Rotary Kiln

The mixing, extrusion, drying, and screening procedure described in Example 17 was repeated 10 more times to generate an additional 33.4 kg of dried, screened extrudate, which were combined. 25.73 kg of the combined dried & screened extrudate was then pyrolyzed in a continuous rotary kiln, with a continuous nitrogen purge (counter current flow vs. the extrudate), with a continuous feed of dried extrudate at approximately 0.5 kg/hour, with product collected at a number of set point conditions summarized in Table 19. The rotary kiln was electrically heated. The temperature set points for the external heaters are shown in Table 19, along with the calculated residence time of the material in the heating zone. The temperature and residence time were adjusted to influence the surface area of the product. A total of 12.47 kg of pyrolyzed product was collected, for a simple “as is” mass-based yield of 48.5%.

Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the continuous-pyrolyzed extrudates had 2.3 wt. % moisture, giving a dry-basis yield of 12.18 kg. Since the dried extrudate starting material for the pyrolysis had a moisture level of 17.7 wt. %, the 25.73 kg represents 21.18 kg on a dry basis, and thus the yield of the pyrolysis on a dry basis is 57.5% (12.18 kg/21.18 kg). On a dry basis, the dried extrudate starting material for the pyrolysis is 40 wt. % carbon black and 60 wt. % binder. Assuming the mass of carbon black is unchanged by the pyrolysis, then on a dry basis the pyrolyzed extrudates have a carbon black content of 69.6 wt. % and a carbonized binder content of 30.4 wt. %.

The pyrolyzed extrudates were analyzed for BET surface area and radial piece crush strength, the results are shown in Table 19.

TABLE 19 Properties of Carbon Black Extrudate Pyrolyzed in a Continuously Operated Rotary Kiln Continuous Calculated N₂ BET Radial Rotary Kiln Temperature Residence Specific Piece Pyrolyzed Set Point in Time in Surface Crush Extrudate Heating Zone Heating Zone Area Strength Sample Number (° C.) (minutes) (m²/g) (N/mm) 18.1 820 63 219 11.0 18.2 820 44 208 10.5 18.3 800 44 202 10.8 18.4 780 44 188 11.3 18.5 760 44 188 15.0 18.6 780 33 176 9.5 18.7 820 33 181 11.7

Example 19 Hydrodeoxygenation of Glucaric Acid Dilactone to Adipic Acid

Suitably concentrated aqueous solutions of rhodium nitrate and platinum nitrate were added together to carbon black powder (crushed from carbon black pellets) by incipient wetness impregnation and agitated to impregnate supports. The samples were dried in an oven at 60° C. overnight, and reduced at 350° C. under a forming gas (5% H₂ and 95% N₂) atmosphere for 4 hours with 2° C./min temperature ramp rate to produce catalysts with a composition of 1.0 wt. % Rh and 2.0 wt. % Pt. By using other carbon blacks supports, Rh and Pt precursors, and adjusting amount of Rh and Pt in solution, different catalysts with various Rh and Pt loadings on a variety of particles from extrudates were prepared in a similar manner.

These catalysts were tested for hydrodeoxygenation of glucaric acid dilactone using the following testing protocol. Catalyst (16 mg) was weighed into a glass vial insert followed by addition of a solution (125 μl) containing glucaric acid dilactone (0.80 M), HBr (0.80 M), and water (2.0 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with hydrogen and pressurized to 6307 kPa (900 psig) at room temperature. Reactor was heated to 120° C. and maintained at 120° C. for 1 hour while vials were shaken. Reactor was then heated to 160° C. and maintained at 160° C. for 2 hours while vials were shaken. After that, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was slowly released. The glass vial insert was removed from reactor and centrifuged. The clear solution was hydrolyzed with NaOH, diluted with deionized water, and analyzed by ion chromatography to determine the yield of adipic acid. The properties of the carbon black starting materials and results of the reaction screening are presented in Table 20.

TABLE 20 Adipic Adipic Acid Surface Mean Pore Pore Acid Selec- Area Diameter Volume Yield tivity Support (m²/g) (Å) (cm³/g) (%) (%) Cabot MONARCH 25 277 0.1 75 83 120 Cabot MONARCH 30 176 0.1 81 91 280 Timcal ENSACO 64 140 0.24 92 99 250P Cabot MONARCH 102 138 0.3 87 97 570 Cabot MONARCH 181 121 0.38 89 99 700 Cabot VULCAN 224 161 0.43 86 99 XC72 Sid Richardson SC159 234 182 0.81 75 86

Example 20 Testing of Rh/Pt Carbon Black Extrudate Catalysts in a Fixed-Bed Reactor for Hydrodeoxygenation of Glucaric Acid to Adipic Acid

Cabot VULCAN XC72 carbon black particles used in this experiment were 150 to 300 μm sized particles crushed and sieved from extrudate pellets prepared from the method described in previous examples. Reactions were conducted in a 6.4 mm (0.25-inch) OD by 38 cm long zirconium tube with co-current down-flow of gas and liquid. Catalyst beds were vibration packed with 200 to 300 μm sized glass beads at the top to approximately 5 cm depth, followed by catalyst (28 cm bed depth containing 1.9 g, 0.90 wt. % Rh+2.1 wt. % Pt on carbon black particles, 150 to 300 μm particle size), then 200 to 300 μm sized glass beads at the bottom to approximately 5 cm depth. Quartz wool plugs separated the catalyst bed from the glass beads.

The packed reactor tube was clamped in an aluminum block heater equipped with PID controller. Gas (compressed hydrogen) and liquid flows were regulated by mass flow controller and HPLC pump, respectively. Substrate solution contains 0.80M D-glucaric acid-1,4:6,3-dilactone, 0.40M HBr and 2.0M water in acetic acid. A back pressure regulator controlled reactor pressure as indicated in Table 21. External temperature of top half reactor and bottom half reactor was controlled at 110° C. and 160° C. respectively. The catalyst was tested for 350 hours on stream and showed stable performance. Table 21 describes the fixed bed reactor conditions and resultant catalyst performance.

TABLE 21 Gas Glucaric acid Glucaric acid Reactor Liquid flowrate/ dilactone Adipic Reactor block dilactone pressure/ flowrate/ mL min⁻¹ conversion/ acid yield/ Test temperature/° C. concentration/M psi mL min⁻¹ (STP) % % 1 110/160 0.80 1000 0.050 50 90 42

Example 21 Hydrodeoxygenation of 1,2,6-Hexanetriol to 1,6-Hexanediol

Suitably concentrated aqueous solutions of Pt(NO₃)_(x) and H₄SiO₄*12WO₃ or PtONO₃ and H₄SiO₄*12WO₃ were added to approximately 50 mg of ENSACO 250G carbon and agitated to impregnate the supports. The samples were dried in an oven at 40° C. overnight under static air and then reduced at 350° C. under forming gas (5% H₂ and 95% N₂) atmosphere for 3 hours. The final catalysts had a metal content of approximately 4.09 wt. % Pt and 3.42 wt. % W.

These catalysts were tested for 1,2,6-hexanetriol hydrodeoxygenation using the following catalyst testing protocol. Catalyst (approximately 10 mg) was weighed into a glass vial insert followed by addition of an aqueous 1,2,6-hexanetriol solution (200 μl of 0.8 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with hydrogen and pressurized to 4721 kPa (670 psig) at room temperature. The reactor was heated to 160° C. and maintained at the respective temperature for 150 minutes while vials were shaken. After 150 minutes, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was then slowly released. The glass vial insert was removed from the reactor and centrifuged. The solution was diluted with methanol and analyzed by gas chromatography with flame ionization detection. The results are shown in Table 22.

TABLE 22 Surface Mean Pore Pore Area Diameter Volume Pt W Yield Selectivity Support (m²/g) (Å) (cm³/g) Precursor Precursor (%) (%) ENSACO 250G 64 140 0.24 Pt(NO₃)₂ H₄SiO₄*12WO₃ 27 64 ENSACO 250G 64 140 0.24 PtONO₃ H₄SiO₄*12WO₃ 47 69

Example 22 Hydrodeoxygenation of 1,2,6-Hexanetriol to 1,6-Hexanediol

A suitably concentrated aqueous solution of ammonium metatungstate, H₂₆N₆W₁₂O₄₀ was added to approximately 500 mg of ENSACO 250G and agitated to impregnate the carbon black support. The sample was thermally treated at 600° C. under a nitrogen atmosphere for 3 hours with 5° C./min temperature ramp rate. Suitably concentrated aqueous solutions of Pt(NMe₄)₂(OH)₆ was added to 50 mg of the above sample and agitated to impregnate the carbon supports. The samples were dried in an oven at 40° C. overnight under static air and then reduced at 250° C. under forming gas (5% H₂ and 95% N₂) atmosphere for 3 hours with 5° C./min temperature ramp rate. The final catalysts had a metal content of approximately 4.5 wt. % Pt and 2 wt. % W.

These catalysts were tested for 1,2,6-hexanetriol hydrodeoxygenation using the following catalyst testing protocol. Catalyst (approximately 10 mg) was weighed into a glass vial insert followed by addition of an aqueous 1,2,6-hexanetriol solution (200 μl of 0.8 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with hydrogen and pressurized to 4721 kPa (670 psig) at room temperature. The reactor was heated to 160° C. and maintained at the respective temperature for 150 minutes while vials were shaken. After 150 minutes, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was then slowly released. The glass vial insert was removed from the reactor and centrifuged. The clear solution was diluted with methanol and analyzed by gas chromatography with flame ionization detection. The results are shown in Table 23.

TABLE 23 Surface Mean Pore Pore Area Diameter Volume Pt W Yield Selectivity Support (m²/g) (Å) (cm³/g) Precursor Precursor (%) (%) ENSACO 250G 64 140 0.24 Pt(NMe₄)₂(OH)₆ H₂₆N₆W₁₂O₄₀ 38 88

Example 23 Hydrodeoxygenation of 1,2,6-Hexanetriol to 1,6-Hexanediol

Suitably concentrated aqueous solutions of ammonium metatungstate, H₂₆N₆W₁₂O₄₀ were added to approximately 500 mg of carbon black materials and agitated to impregnate the carbon black supports. The samples were thermally treated at 600° C. under a nitrogen atmosphere for 3 hours with 5° C./min temperature ramp rate. Suitably concentrated aqueous solutions of Pt(NMe₄)₂(OH)₆ were added to approximately 50 mg of the above samples and agitated to impregnate the carbon supports. The samples were dried in an oven at 60° C. under static air and then reduced at 350° C. under forming gas (5% H₂ and 95% N₂) atmosphere for 3 hours with 5° C./min temperature ramp rate. The final catalysts had a metal content of approximately 5.7 wt. % Pt and 1.8 wt. % W.

These catalysts were tested for 1,2,6-hexanetriol hydrodeoxygenation using the following catalyst testing protocol. Catalyst (approximately 10 mg) was weighed into a glass vial insert followed by addition of an aqueous 1,2,6-hexanetriol solution (200 μl of 0.8 M). The glass vial insert was loaded into a reactor and the reactor was closed. The atmosphere in the reactor was replaced with hydrogen and pressurized to 4721 kPa (670 psig) at room temperature. The reactor was heated to 160° C. and maintained at the respective temperature for 150 minutes while vials were shaken. After 150 minutes, shaking was stopped and reactor was cooled to 40° C. Pressure in the reactor was then slowly released. The glass vial insert was removed from the reactor and centrifuged. The clear solution was diluted with methanol and analyzed by gas chromatography with flame ionization detection. Results are shown in Table 24.

TABLE 24 Surface Mean Pore Pore Area Diameter Volume Pt W Yield Selectivity Support (m²/g) (Å) (cm³/g) Precursor Precursor (%) (%) ENSACO 250G 64 140 0.24 Pt(NMe₄)₂(OH)₆ H₂₆N₆W₁₂O₄₀ 52 71 Orion HIBLACK 109 155 0.32 Pt(NMe₄)₂(OH)₆ H₂₆N₆W₁₂O₄₀ 28 68 40B2

Example 24 Small Scale Batch Reactor Experiments for Amination of 1,6-Hexanediol to Produce 1,6-Hexamethylenediamine

Amination of 1,6-Hexanediol to produce 1,6-Hexamethylenediamine—Analytical Details

Product composition was determined by HPLC analysis using a Thermo Ultimate 3000 dual analytical chromatography system. Hexamethylenediamine (HMDA), hexamethyleneimine (HMI) and pentylamine were eluted with a mobile phase consisting of H₂O/MeCN/TFA and detected using a charged aerosol detector (CAD). 1,6-Hexanediol (HDO) was eluted with a mobile phase consisting of H₂O/MeCN/TFA and detected using a refractive index detector (RI). In certain examples an internal standard, N-methyl-2-pyrrolidone (NMP), was used in the substrate feed to correct for variations in product effluent concentration due to NH₃ off-gassing. NMP was eluted with a mobile phase consisting of H₂O/MeCN/TFA and detected by UV at 210 nm. All products were quantified by comparison to calibration standards. Selectivity is reported as the yield of HMDA divided by the sum of HMDA and pentylamine.

Experiment 1

Preparation of Supported Ru Catalysts

A suitably concentrated aqueous solution of Ru(NO)(NO₃)₃ was added to a 96 vial array of carbon supports containing 10 or 20 mg of support in each vial. The volume of ruthenium solution was matched to equal the pore volume of the support. Each sample was agitated to impregnate the support. The samples were dried in an oven at 60° C. for 12 hours under a dry air purge. The catalysts were reduced under forming gas (5% H₂ and 95% N₂) at 250° C. for 3 hours using a 2° C./min temperature ramp rate. The final catalysts were composed of 2 weight percent ruthenium.

Catalyst Screening Procedure

A substrate solution consisting of 0.7 M 1,6-hexanediol in concentrated aqueous NH₄OH was added to an array of catalysts prepared as described above. The vials were covered with a Teflon pinhole sheet, a silicone pinhole mat, and a steel gas diffusion plate. The reactor insert was placed in a pressure vessel and purged 2× with NH₃ gas. The pressure vessel was charged to 690 kPa (100 psi) with NH₃ gas and then to 4700 kPa (680 psi) with N₂ at ambient temperature. The reactor was placed on a shaker and vortexed at 800 rpm at 160° C. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen prior to being unsealed. The samples were diluted with water, mixed, and then centrifuged to separate catalyst particles. Aliquots were removed from the supernatant and diluted further with dilute aqueous trifluoroacetic acid for analysis by HPLC. Results are summarized below in Table 25.

TABLE 25 Surface Mean Pore Pore Catalyst HDO HMDA Pentylamine Area Diameter Volume Amount Conversion Yield Yield Support (m²/g) (Å) (cm³/g) (mg) (%) (%) (%) Selectivity Asbury 5346R 80 145 0.28 10 79.8 16.5 0.0 99.8 Asbury 5346R 80 145 0.28 20 99.1 25.1 0.5 97.9 ENSACO 150G 47 136 0.17 10 80.8 16.4 0.1 99.5 ENSACO 150G 47 136 0.17 20 95.5 24.5 0.7 97.4 ENSACO 250G 64 140 0.24 10 78.6 16.3 0.0 100 ENSACO 250G 64 140 0.24 20 94.4 26.0 0.5 98.2 ENSACO 260G 63 104 0.18 10 74.7 15.4 0.0 100 ENSACO 260G 63 104 0.18 20 93.3 24.0 0.5 98.1 HP160 158 208 0.87 10 81.7 11.9 0.0 100 HP160 158 208 0.87 20 98.3 18.3 0.1 99.2 Orion HI-BLACK 193 157 0.66 10 91.0 18.8 0.2 99.1 50L Orion HI-BLACK 193 157 0.66 20 100 21.7 0.7 96.8 50L Sid Richardson 234 182 0.81 10 90.3 14.7 0.0 100 SC159 Sid Richardson 234 182 0.81 20 99.3 17.3 0.4 97.9 SC159 Sid Richardson 146 222 0.87 10 93.2 19.5 0.1 99.5 SR155 Sid Richardson 146 222 0.87 20 100 19.7 0.4 98.1 SR155

Experiment 2

Preparation of Supported Ru/Re Catalysts

Suitably concentrated aqueous solutions of Ru(NO)(NO₃)₃ containing varying amounts of HReO₄ were added to 0.15 g of a support and agitated to impregnate the support. The volume of metal solution was matched to equal the pore volume of the support. The samples were dried in an oven at 60° C. for 3 hours under a dry air purge. Catalyst amounts from 10-20 mg were weighed in to glass vials of a 96 vial array. The catalysts were reduced under forming gas (5% H₂ and 95% N₂) at 60° C. for 3 hours then at 250° C. for 3 hours using a 2° C./min temperature ramp rate. The final catalysts were composed of 4.04 weight percent ruthenium containing various rhenium loadings of 0, 0.4, 0.7, and 1.9 wt. %.

Catalyst Screening Procedure

A substrate solution consisting of 1.549M 1,6-hexanediol in concentrated aqueous NH₄OH was added to an array of catalysts prepared as described above. The vials were covered with a Teflon pinhole sheet, a silicone pinhole mat, and a steel gas diffusion plate. The reactor insert was placed in a pressure vessel and purged 2× with NH₃ gas. The pressure vessel was charged to 690 kPa (100 psi) with NH₃ gas and then to 4700 kPa (680 psi) with N₂ at ambient temperature. The reactor was placed on a shaker and vortexed at 800 rpm at 160° C. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen prior to being unsealed. The samples were diluted with water, mixed, and then centrifuged to separate catalyst particles. Aliquots were removed from the supernatant and diluted further with dilute aqueous trifluoroacetic acid for analysis by HPLC. Results are outline below in Table 26.

TABLE 26 Hexanediol to Hexamethylenediamine using Ru/Re/Carbon HP-160 Catalysts HDO Pentyl- Catalyst Conver- HMDA amine HMDA/ Amount Ru Re sion Yield Yield Pentyl- Entry (mg) (wt. %) (wt. %) (%) (%) (%) amine 1 20 4.04 0.0 95.8 20.2 1.4 14.5 2 20 4.04 0.4 98.7 23.2 1.3 18.1 3 20 4.04 0.7 99.4 23.4 1.0 23.3 4 20 4.04 1.9 97.4 20.3 0.4 51.8 5 10 4.04 0.0 79.5 14.4 0.6 26.1 6 10 4.04 0.4 90.4 20.1 0.7 27.9 7 10 4.04 0.7 92.6 20.7 0.6 35.8 8 10 4.04 1.9 78.3 11.5 0.0

Experiment 3

Preparation of Ni/Ru Catalysts Supported on ENSACO 250G

Suitably concentrated aqueous solutions containing Ni(NO₃)₂ and/or Ru(NO)(NO₃)₃ were added by incipient wetness impregnation to approximately 0.4 g of a carbon black support and agitated to impregnate the support. The volume of metal solution was matched to equal the pore volume of the support. Each catalyst was thermally treated under N₂ in a tube furnace at 60° C. for 12 hours then at 300° C. for 3 hours using a 5° C./min temperature ramp rate.

Catalyst amounts from 15-25 mg were weighed in to glass vials of a 96 vial array. The catalysts were reduced under forming gas (5% H₂ and 95% N₂) at 450° C. for 3 hours using a 2° C./min temperature ramp rate. Catalysts were passivated with 1% O₂ in N₂ at room temperature before removing from the tube furnace.

Catalyst Screening Procedure A

A substrate solution consisting of 0.7M 1,6-hexanediol in concentrated aqueous NH₄OH was added to an array of catalysts prepared as described above. The vials were covered with a Teflon pinhole sheet, a silicone pinhole mat, and a steel gas diffusion plate. The reactor insert was placed in a pressure vessel and purged 2× with NH₃ gas. The pressure vessel was charged to 690 kPa (100 psi) with NH₃ gas and then to 4700 kPa (680 psi) with N₂ at ambient temperature. The reactor was placed on a shaker and vortexed at 800 rpm at 160° C. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen prior to being unsealed. The samples were diluted with water, mixed, and then centrifuged to separate catalyst particles. Aliquots were removed from the supernatant and diluted further with dilute aqueous trifluoroacetic acid for analysis by HPLC. Results are summarized below in Table 27.

TABLE 27 HDO Pentyl- Catalyst Conver- HMDA amine Amount Ni Ru sion Yield Yield Selec- Entry (mg) (wt. %) (wt. %) (%) (%) (%) tivity 1 15 12 0 35.8 1.9 0.0 98.4 2 15 0 0.56 66.1 9.6 0.3 97.4 3 15 4 0.56 74.3 17.3 0.3 98.5 4 15 8 0.56 77.3 22.7 0.3 98.7 5 15 12 0.56 85.9 25.3 0.4 98.6 6 25 12 0 54.0 7.7 0.1 99.1 7 25 0 0.56 82.7 18.9 0.5 97.2 8 25 4 0.56 89.1 29.0 0.8 97.5 9 25 8 0.56 92.8 31.4 0.7 97.7 10 25 12 0.56 94.7 30.1 0.7 97.6

Catalyst Screening Procedure B

Passivated catalysts were reactivated in water under H₂ at 180° C. for 3 hours. Most of the water was removed from each catalyst leaving behind enough to act as a protective layer. The catalysts were then screened as described above in Procedure A. Results are summarized below in Table 28.

TABLE 28 HDO Pentyl- Catalyst Conver- HMDA amine Amount Ni Ru sion Yield Yield Selec- Entry (mg) (wt. %) (wt. %) (%) (%) (%) tivity 1 15 12 0 49.2 7.2 0.00 100.0 2 15 0 0.56 67.0 11.2 0.06 99.5 3 15 4 0.56 73.7 18.2 0.07 99.7 4 15 8 0.56 86.8 25.5 0.38 98.5 5 15 12 0.56 86.0 23.8 0.33 98.7 6 25 12 0 73.3 16.0 0.00 100.0 7 25 0 0.56 83.8 18.3 0.84 95.6 8 25 4 0.56 93.5 28.1 1.22 95.9 9 25 8 0.56 94.0 27.8 1.07 96.3 10 25 12 0.56 96.1 27.3 1.15 96.0

Fixed Bed Experiments

Preparation of 2 wt. % Ru on Carbon ENSACO 250G

A carbon extrudate, prepared from carbon black ENSACO 250G and a carbohydrate binder, was crushed and sized to 150-300 um. A suitably concentrated aqueous solution of Ru(NO)(NO₃)₃ was added to 4.77 g of the crushed extrudate and agitated to impregnate the support. The volume of metal solution was matched to equal the pore volume of the support. The samples were dried in an oven at 60° C. for 12 hours under a dry air purge. The catalyst was reduced under forming gas (5% H₂ and 95% N₂) at 250° C. for 3 hours using a 2° C./min temperature ramp rate. The catalyst was washed with water and again sized to 106-300 um to remove any fines that may have been generated during the metal impregnation step.

Preparation of 10.5 wt. % Ni and 0.45 wt. % Ru on Carbon ENSACO 250G

A carbon extrudate, prepared from carbon black ENSACO 250G and a carbohydrate binder, was crushed and sized to 106-300 um. A suitably concentrated aqueous solution containing Ni(NO₃)₂.6H₂O and Ru(NO)(NO₃)₃ was added to 10 g of the crushed extrudate and agitated to impregnate the support. The volume of metal solution was matched to equal the pore volume of the support. The catalyst was dried in an oven at 60° C. for 12 hours under a dry air purge then thermally treated under N₂ at 300° C. for 3 hours. The catalyst was reduced under forming gas (5% H₂ and 95% N₂) at 450° C. for 3 hours using a 2° C./min temperature ramp rate. After cooling to room temperature the catalyst was passivated with 1% O₂ in N₂ at room temperature before removing from the tube furnace. The catalyst was washed with water and again sized to 106-300 um to remove any fines that may have been generated during the metal impregnation step.

2 wt. % Ru on Carbon Catalyst

The reaction was performed in a 6.4 mm (0.25-inch) OD by 570 mm long 316 stainless steel tube with a 2 um 316 stainless steel frit at the bottom of the catalyst bed. The reactor was vibration packed with 1 g of SiC beads (90-120 um) followed by 3 g of a 2% by weight ruthenium on carbon ENSACO 250G catalyst (100-300 um) and finally 2.5 g of SiC beads at the top. A 6.4 mm (0.25-inch) layer of glass wool was used between each layer. The packed reactor tube was vertically mounted in an aluminum block heater equipped with PID controller. An HPLC pump was used to deliver liquid feed to the top of the reactor and a back pressure regulator was used to control reactor pressure. The reaction was run at 160° C. Product effluent was collected periodically for analysis by HPLC. No decline in catalyst activity was observed after 1650 h.

Three different feed compositions were investigated at 160° C. with a reactor pressure ranging from 800-1000 psi. In all cases N-methyl-2-pyrrolidone (NMP) was used as an internal standard.

Feed 1: 0.7M 1,6-hexanediol and 0.14M NMP in concentrated NH4OH.

Feed 2: 0.7M 1,6-hexanediol, 0.14M hexamethyleneimine, and 0.14M NMP in concentrated NH4OH.

Feed 3: 1.54M 1,6-hexanediol, 0.308M hexamethyleneimine, and 0.308M NMP in concentrated NH₄OH.

The results are summarized below in Table 29.

10.5 wt. % Ni/0.45 wt. % Ru on Carbon Catalyst

The reaction was performed as described above for the Ru only catalyst. A total of 3 g of Ni/Ru catalyst was loaded into the reactor and reactivated at 180° C. under H₂ before introduction of the feed solution. No decline in catalyst activity was observed after 650 h. Results are summarized below in Table 29.

TABLE 29 Feed Reactor HDO HMDA HMI Pentylamine Rate Pressure Conversion Yield Yield Yield Catalyst Source (mL/min) (psi) (%) (%) (%) (%) Selectivity 2 wt. % Ru Feed 1 0.2 800 85 23 11 1.5 93.9 2 wt. % Ru Feed 2 0.2 800 83 29 18 1.6 94.8 2 wt. % Ru Feed 3 0.15 1000 90 36 21 2.6 93.3 10.5 wt. % Feed 2 0.2 800 83 26 17 0.5 98.1 Ni/0.45% Ru

Example 25 Preparation of Carbon Black Extrudates using Different Cellulosic Binder Components

Additional carbon black extrudates were prepared using the binder mixtures indicated in Table 30. The procedure for the preparation of samples 1-21 is as follows: 900 g of a binder solution containing glucose and polymeric binder (with the wt. % content listed in Table 30) was added to 400 g carbon black powder (Sid Richardson SC159) in a Simpson Laboratory Mix Muller, which was run for 2 hours to ensure good mixing and kneading of the material. The material was then loaded into a 2.54 cm (1-inch) Bonnot “BB Gun” Catalyst Extruder and extruded into spaghetti like strings with about a 1.6 mm diameter. These strings were dried under a dry air purge at 120° C. in an oven overnight and then pyrolyzed in batch mode under a nitrogen atmosphere at 800° C. for 2 hours with a temperature ramp of 30° C./minute. Sample 22 was prepared in accordance with this procedure with the exception that the binder solution did not contain a polymeric binder. Sample 23 was also prepared in accordance with this procedure with the exception that the binder solution did not contain glucose.

The polymeric binders listed in Table 30 are the following:

-   -   Dow CELLOSIZE EP-09 (EP-09), hydroxyethylcellulose;     -   Dow METHOCEL K100LV (K100LV), hydroxypropylmethylcellulose;     -   Dow METHOCEL A4C (A4C), methylcellulose;     -   Dow METHOCEL F50 (F50), hydroxypropylmethylcellulose;     -   Ashland NATROSOL 250GR (250GR), hydroxyethylcellulose;     -   Ashland NATROSOL 250JR (250JR), hydroxyethylcellulose;     -   Ashland NATROSOL 250LR (250LR), hydroxyethylcellulose; and     -   Dow CELLOSIZE QP-40 (QP-40), hydroxyethylcellulose.

TABLE 30 Radial Glucose Polymeric Vis- Piece N₂ BET Binder Binder cosity Crush Surface Sam- wt. % in Polymeric wt. % in (mPa · s, Strength Area ple Solution Binder Solution cPs) (N/mm) (m²/g) 1 47.2 EP-09 5.7 10 9.7 180 2 48.1 EP-09 3.8 10 10.1 179 3 49.0 EP-09 2.0 10 18.7 175 4 47.2 K100LV 5.7 100 10.6 172 5 48.1 K100LV 3.8 100 10.5 170 6 49.0 K100LV 2.0 100 11.1 182 7 47.2 A4C 5.7 400 9.7 174 8 48.1 A4C 3.8 400 10.6 173 9 49.0 A4C 2.0 400 10.4 176 10 47.2 F50 5.7 50 9.2 174 11 48.1 F50 3.8 50 10.7 177 12 49.0 F50 2.0 50 9.5 182 13 47.2 250GR 5.7 150 11.4 171 14 48.1 250GR 3.8 150 11.1 163 15 49.0 250GR 2.0 150 10.2 175 16 47.2 250JR 5.7 20 12.5 167 17 48.1 250JR 3.8 20 14.3 171 18 49.0 250JR 2.0 20 21.5 171 19 47.2 250LR 5.7 12 14.8 170 20 48.1 250LR 3.8 12 10.1 170 21 49.0 250LR 2.0 12 9.6 174 22 49.0 — — — 10.2 — 23 — QP-40 4.0 125 0.5 —

The viscosity reported in Table 30 is the approximate viscosity of a 2 wt. % aqueous solution of the polymeric binder at 25° C. The extrudates were analyzed for BET specific surface area and radial piece crush strength. The results of these analyses are also provided in Table 30. Pore volume and mean pore diameter (BJH method) were also measured for these pyrolyzed extrudates. The pore volume for these samples ranged from approximately 0.3 to 0.4 cm³/g. The mean pore diameter for these samples ranged from approximately 13 to 16 nanometers (130 to 160 Angstroms).

The results in Table 30 show that radial piece crush strengths of most of the samples are approximately 10-12 N/mm, with the exception of the lower viscosity hydroxyethylcellulose. The extrudates prepared with either Dow CELLOSIZE EP-09 hydroxyethylcellulose and Ashland NATROSOL 250JR hydroxyethylcellulose exhibit greater radial piece crush strength as the weight percent of the polymeric binder decreases from 5.7 to 2.0 wt. %.

Example 26 Evaluation of Belt Drying Conditions on Final Extrudate Crush Strength

An aqueous solution containing 101.5 g of Ashland Natrosol Hydroxyethylcellulose 250 JR (viscosity 20 mPa·s (cP) at 2% in H₂O (25° C.)), and 2739 g glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) in 2258 ml deionized water was stirred in a heated drum at approximately 60° C. fitted with a mixer for approximately 24 hours. This resultant solution was added over 8 minutes to 2281 g of Sid Richardson SC159 carbon black powder in a 45.7 cm (18 inch) diameter Simpson mix-muller, the mixture was then mixed for a further 20 minutes in the mix-muller. The material was then loaded into a 5.7 cm (2.25-inch) diameter Bonnot Catalyst Extruder, fitted with 5 dies with 26 cylindrical holes each 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and no spacer, and extruded into spaghetti-like strings. The extrudate was then dried on a commercial scale continuous industrial belt dryer (200 cm (118 inches) wide, 1219 cm (480 inches) heated zone (3 independent heating zones, forced hot air, each 406 cm (160 inches) long), with a conveyor belt of perforated steel sheets), equipped with three hot air temperature stages set at 43° C., 110° C. and 110° C. The extrudate was dried on the belt dryer by passing the extrudate through the 3 temperature zones with an aggregate residence time of 75 minutes. Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the belt-dried extrudates had 17.0% moisture remaining after the belt drying process. The extrudates were further dried in an oven at 120° C. overnight, reducing the residual moisture level to 11.7 wt. % as measured on a moisture balance using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample. The extrudates were then pyrolyzed in batch mode using a 12.7 cm (5-inch) quartz tube rotating at 4.0 rpm under a nitrogen atmosphere at 800° C. for 2 hours with a temperature ramp of 30° C./minute. The resulting extrudate (1.4 mm diameter×3 mm to 7 mm length) was characterized with a radial piece crush strength in the range from about 7 N/mm to about 10 N/mm, which is much lower than the crush strength achievable with similar formulations prepared at laboratory scale and quickly dried in a laboratory oven at 130° C., as shown in Example 25, sample 18. The resulting extrudate was also characterized with a N₂ BET specific surface area of 158 m²/g, a N₂ BJH adsorption specific pore volume of 0.37 cm³/g, and a N₂ BJH adsorption mean pore diameter of 14.9 nm (149 Angstroms).

Example 27 Preparation of Carbon Black Extrudates using Improved Continuous Belt Drying and Batch Pyrolysis

An aqueous solution containing 101.5 g of Ashland NATROSOL Hydroxyethylcellulose 250 JR (viscosity 20 mPa·s (cP) at 2% in H₂O (25° C.)), and 2739 g glucose (ADM Corn Processing, Dextrose Monohydrate 99.7 DE with 91.2 wt. % Glucose content) in 2264 ml deionized water was stirred at in a heated drum fitted with a mixer for 6.5 hours. This resultant solution was added over 3.5 minutes to 2272 g of Sid Richardson SC159 carbon black powder in a 45.7 cm (18 inch) diameter Simpson mix-muller, the mixture was then mixed for a further 20 minutes in the mix-muller. The material was then loaded into a 5.7 cm (2.25-inch) diameter Bonnot Catalyst Extruder, fitted with 5 dies with 26 cylindrical holes each 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and no spacer, and extruded into spaghetti-like strings. Approximately 7.4 kg of the extrudate was dried on a commercial scale continuous industrial belt dryer 200 cm (118 inches) wide, 1219 cm (480 inches) heated zone (3 independent heating zones, forced hot air, each 406 cm (160 inches) long), with a conveyor belt of perforated steel sheets), with the three hot air temperature stages set at 110° C., 120° C., and 120° C. The extrudate was dried on the belt dryer by passing a thin bed (approximately 1.27 cm (0.5 inches) in depth) of the extrudate through the three temperature zones with a cumulative residence time of 75 minutes (25 minutes per zone) to produce 5.2 kg of dried extrudate. Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the belt-dried extrudates had 11.1 wt. % moisture remaining. The extrudates were further dried in an oven at 120° C. overnight, reducing the residual moisture level to 10.0 wt. % as measured on a moisture balance using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample. The carbon black extrudates were pyrolyzed in batch mode under a nitrogen atmosphere (continuous nitrogen purge) at 800° C. for 2 hours with a temperature ramp of 30° C./minute. The resulting extrudate (1.4 mm diameter×3-7 mm length) was characterized with a radial piece crush strength of 23 N/mm, which was significantly higher than was achieved in Example 26. The resulting extrudate was also characterized with a N₂ BET specific surface area of 193 m²/g, a N₂ BJH adsorption specific pore volume of 0.39 cm³/g, and a N₂ BJH adsorption mean pore diameter of 14.9 nm (149 Angstroms).

Example 28 Effect of Drying Conditions and Time between Drying and Calcining (Pyrolysis) on Final Extrudate Crush Strength

A set of experiments was designed to study the effect of drying conditions, residual moisture level, and the time elapsed between drying and pyrolysis (calcining) of the extrudates, on the strength of the final pyrolyzed (calcined) extrudates. The results are shown in Tables 31 and 32 below.

Extrudates were dried in conventional laboratory oven with a dry air purge, at the drying temperature and for the time shown in the table below. Residual moisture content (wt. %) of the extrudates was measured on moisture balance at 160° C. (5 g sample, dried to constant weight defined as weight change less than 1 mg per 3 minutes, typically one hour per sample).

TABLE 31 Residual Moisture Content (wt. %) Dependence on Drying Time (hours) & Temperature (° C.) Drying Temperature Drying Time Residual Moisture Content (° C.) (hours) (wt. %) 70 1 24.5 70 2 16.4 70 3 13.4 70 4 12.7 70 6 11.0 70 22 11.5 100 1 14.5 100 2 10.0 100 3 9.5 100 4 10.1 100 6 9.4 100 22 9.7 130 1 8.6 130 2 8.9 130 3 9.0 130 4 8.0 130 6 8.0 130 22 6.7

After storage in a water-tight container for the “Shelf Life” (elapsed time between drying and pyrolysis) shown in Table 32 below, the extrudates were pyrolyzed (calcined) in a static furnace under nitrogen purge, using a temperature ramp rate, from ambient temperature to 800° C., of 30° C. per minute, followed by holding at 800° C. for 2 hours, then cooling to ambient temperature. The radial piece crush strength (N/mm) was then measured for each sample of pyrolyzed (calcined) extrudates. The results are shown in Table 32 below.

TABLE 32 Effect of Residual Moisture and Elapsed Time Between Drying and Pyrolysis on the Final Extrudate Crush Strength Shelf Life Shelf Life Radial Drying Mois- (time between (time between Piece Tempera- Drying ture drying and drying and Crush ture Time Content pyrolysis, pyrolysis, Strength (° C.) (hours) (wt. %) hours) days) (N/mm) 70 2 16.4 3 0.1 13.6 70 2 16.4 27 1.1 13.4 70 2 16.4 99 4.1 5.7 70 2 16.4 388 16.2 3.0 70 3 13.4 20 0.8 12.0 70 3 13.4 50 2.1 9.8 70 3 13.4 406 16.9 3.8 70 4 12.7 19 0.8 14.3 70 4 12.7 49 2.0 11.4 70 4 12.7 170 7.1 9.5 70 4 12.7 405 16.9 9.6 70 6 11.0 41 1.7 10.7 70 6 11.0 411 17.1 12.6 100 1 14.5 4 0.2 9.2 100 1 14.5 28 1.2 9.9 100 1 14.5 100 4.2 9.2 100 1 14.5 389 16.2 3.8 100 2 10.0 3 0.1 12.1 100 2 10.0 27 1.1 10.5 100 2 10.0 99 4.1 9.2 100 2 10.0 388 16.2 12.6 100 3 9.5 20 0.8 8.5 100 3 9.5 50 2.1 10.0 100 3 9.5 171 7.1 10.1 100 3 9.5 406 16.9 12.1 100 6 9.4 41 1.7 12.2 100 6 9.4 411 17.1 9.8

As the table shows, when the residual moisture content (wt. %) of the dried extrudates was higher than 11 wt. %, there was a decline in the radial piece crush strength (N/mm) of the pyrolyzed (calcined) extrudates with increasing “Shelf Life” (elapsed time between drying and pyrolysis). The reduction in crush strength of the pyrolyzed (calcined) extrudates was especially evident for samples that had residual moisture content (wt. %) of the dried extrudates higher than 13 wt. %. When the residual moisture content (wt. %) of the dried extrudates was lower than 11 wt. %, the crush strength of the pyrolyzed (calcined) extrudates remained high. Surprisingly, the residual moisture content of the dried extrudates had an effect on the crush strength of the pyrolyzed (calcined) extrudates. When the residual moisture content was above about 11 wt. %, then the crush strength of the pyrolyzed (calcined) extrudates was negatively affected with increasing “Shelf Life” (elapsed time between drying and pyrolysis). However, when the residual moisture content was at or below about 11 wt. %, then the crush strength was not compromised even when the dried extrudates were stored for an extended period of time (2 weeks) before pyrolysis (carbonization).

Example 29 Evaluation of Continuous Belt Drying Conditions and Continuous Rotary Kiln Residence Time and Conditions on Final Pyrolyzed Extrudate Crush Strength

An aqueous solution containing 1.9 kg of Ashland Natrosol Hydroxyethylcellulose 250 JR (viscosity 20 mPa·s (cP) at 2% in H₂O (25° C.)), and 49.9 kg of glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) in 41.4 kg deionized water was stirred in a 35 gallon drum fitted with a mixer and an immersion heater at about 70° C. overnight. 59.5 kg of the resulting solution was added over 10 minutes to 27.21 kg of Sid Richardson SC159 carbon black powder in a 91.4 cm (36 inch) diameter Simpson mix-muller, the mixture was then mixed at high speed for a further 30 minutes in the mix-muller.

The material was then loaded into a 10.16 cm (4 inch) diameter Bonnot Catalyst Extruder fitted with 6 dies, each with 26 cylindrical holes of 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and extruded into spaghetti-like strings. The extrudate was then dried on a commercial scale continuous industrial belt dryer, which was 104.4 cm (41 inches) wide, 330.2 cm (130 inches) heated zone (forced hot air from single main burner split into 3 heating zones, each controlled with valves above the belt to control flow of hot air and valves below the bed to control the exhaust and thus cold air flow, with first and second zones each 114.34 cm (45 inches) long, the third zone 101.6 cm (40 inches) long, with a conveyor belt of steel mesh.

The material was passed through the belt dryer with the three temperature zones set such that the thermocouples in the first, second and third heater zones above the belt were reading 130° C., 170° C. and 225° C., and thermocouples in the first, second and third heater zones below the belt were reading 101° C., 114° C. and 49° C. Thermocouples were inserted into the bed of extrudates on the belt periodically during the drying process, with typical readings of 95° C., 130° C. and 60° C. in the first, second and third heater zones respectively. The belt was run relatively slowly to achieve a total residence time in the heated zones of about 60 minutes. Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 15 minutes) indicated the belt-dried extrudates had 25 wt. % moisture remaining.

The material was passed through the belt dryer for a second time with higher hot air flow rate and with the three temperature zones set such that the thermocouples in the first, second and third heater zones above the belt were reading 132° C., 138° C. and 120° C., and thermocouples in the first, second and third heater zones below the belt were reading 71° C., 88° C. and 32° C. A high air flow rate was used. Thermocouples were inserted into the bed of extrudates on the belt periodically during the drying process, with typical readings of 100° C., 125° C. and 100° C. in the first, second and third heater zones respectively. The belt was run relatively quickly to achieve a total residence time in the heated zones of about 20 minutes. Measurement of residual moisture on a moisture balance (using 5 g of sample, a temperature setting of 160° C. and a time of 30 minutes) indicated the belt-dried extrudates had 9.0 wt. % moisture remaining, which was below the threshold level of 11 wt. % and so met the drying target.

Example 30 Preparation of Carbon Black Extrudates using Continuous Pyrolysis in a Multi-Temperature Zone Rotary Kiln

Dried extrudate material from the large scale preparation described in Example 29 was charged to a vibratory feeder and fed under a nitrogen purge into and through a multi-temperature zone rotary kiln. The three heated zones of the rotary kiln were each 50.8 cm (20 inches) in length, for a total heated length of 152.4 cm (60 inches). The rotary kiln Zone 1/Zone 2/Zone 3 temperatures were set to 450° C./600° C./800° C. respectively. The speed of the screw feeder was adjusted to between 5 kg of extrudate per hour. The angle of inclination and rotation rate of the rotary kiln were adjusted to maintain a desired residence time in the 152.4 cm (60 inch) heated zone of the kiln. The target average residence time was 60 minutes, while the actual average residence time calculated after the run was 50 minutes. A nitrogen purge was also applied to both the entrance and exit of the furnace, and to the product collection vessel. The pyrolyzed extrudate was collected in a collection vessel under a nitrogen purge and volatile products that result from the pyrolysis were sent to a cooled collection vessel (for condensables) for downstream waste processing, with off-gases going to an afterburner.

Table 33 presents the process conditions for the multi-temperature zone rotary kiln. The surface area, pore volume and mean pore diameter, and the crush strength of the resulting pyrolyzed extrudates are shown in Table 34. The crush strength of 15.4 N/mm, was a significant improvement compared with previous Examples that employed continuous belt drying.

TABLE 33 Total Steady Kiln Temperature Residence State Volu- (° C.) Time in the 3 Feed Sample metric Zone Zone Zone Heated Zones Rate Time Feeder Test 1 2 3 (minutes) (kg/hr) (hours) Type 1 450 600 800 50.3 5 2 Vibra- tory

TABLE 34 Steady State N₂ BJH Steady State % fines Product after N₂ BJH Adsorption Product before (sieved sieving to N₂ BET Adsorption Mean Pore Radial Piece sieving on 1 mm remove fines Surface area Pore volume diameter Crush Strength Test (g) screen) (g) (m²/g) (cm³/g) (Å) (N/mm) 1 3,972 1.8 3.90 176 0.30 127 15.4

Example 31 Evaluation of Extrusion Recipe Moisture Content, Continuous Belt Drying Conditions and Continuous Rotary Kiln Residence Time and conditions on Final Pyrolyzed Extrudate Crush Strength

An aqueous solution containing 3.1 kg of Ashland Natrosol Hydroxyethylcellulose 250 JR (viscosity 20 mPa·s (cP) at 2% in H₂O (25° C.)), and 82.9 kg of glucose (ADM Corn Processing, Dextrose Monohydrate 99.7DE with 91.2 wt. % Glucose content) in 36.1 kg deionized water was stirred in a 35 gallon drum fitted with a mixer and an immersion heater at about 70° C. overnight. 46.9 kg of the resulting solution was added over 10 minutes to 27.21 kg of Sid Richardson SC159 carbon black powder in a 91.4 cm (36 inch) diameter Simpson mix-muller, the mixture was then mixed at high speed for a further 30 minutes in the mix-muller.

The material was then loaded into a 10.16 cm (4 inch) diameter Bonnot Catalyst Extruder fitted with 18 dies, each with 26 cylindrical holes of 1.6 mm ( 1/16-inch) internal diameter (JMP Industries, part number 0388P062), and extruded into spaghetti-like strings. The extrudate was then dried on a commercial scale continuous industrial belt dryer, which was 104.14 cm (41 inches) wide, 330.2 cm (130 inches) heated zone (forced hot air from single main burner split into 3 heating zones, each controlled with valves above the belt to control flow of hot air and valves below the bed to control the exhaust and thus cold air flow, with first and second zones each 114.3 cm (45 inches) long, the third zone 101.6 cm (40 inches) long, with a conveyor belt of steel mesh.

The material was passed through the belt dryer twice, with high hot air flow rate and with the three temperature zones set such that the thermocouples in the first, second and third heater zones above the belt were reading 135° C., 177° C. and 149° C., and thermocouples in the first, second and third heater zones below the belt were reading 102° C., 113° C. and 46° C. Thermocouples were inserted into the bed of extrudates on the belt periodically during the drying process, with typical readings of 130° C., 175° C. and 120° C. in the first, second and third heater zones respectively. The belt was run relatively quickly to achieve a total residence time in the heated zones of about 15 minutes per pass, for a total drying residence time of about 30 minutes for the 2 passes. Measurement of residual moisture on a moisture balance (using 5 g of sample, a temperature setting of 160° C. and a time of 30 minutes) indicated the belt-dried extrudates had 9.8 wt. % moisture remaining, which was below the threshold level of 11 wt. % and so met the drying target.

A second batch extrudates was prepared by combining in the mix muller by combining another 46.9 kg of the dextrose/hydroxyethylcellulose/water solution with another 27.21 kg of Sid Richardson SC159 carbon black powder in the 91.4 cm (36 inch) diameter Simpson mix-muller, and repeating the mix-mulling, extrusion and belt drying process (two passes, each 15 minutes) described above. Measurement of residual moisture on a moisture balance (using 5 g of sample, a temperature setting of 160° C. and a time of 30 minutes) indicated the belt-dried extrudates had 8.7 wt. % moisture remaining, which again was below the threshold level of 11 wt. % and so met the drying target.

The whole preparation of the dextrose/hydroxyethylcellulose/water solution, the mix-mulling and extrusion, and the 2-pass belt drying process, as described above, was repeated again to produce two more batches of dried extrudates. Measurement of residual moisture on a moisture balance using the same procedure indicated the third and fourth batches of belt-dried extrudates both had 8.8 wt. % moisture remaining, which again was below the threshold level of 11 wt. % and so met the drying target.

The total combined weight of the 4 batches of dried extrudates was 229 kg. The average moisture content was 9.0%.

Example 32 Preparation of Carbon Black Extrudates using Continuous Pyrolysis in a Multi-Temperature Zone Rotary Kiln

A total of 213.5 kg of dried extrudate material from the four large scale preparations described in Example 31 was charged to an Acrison Model 105X-D volumetric feeder fitted with an open helical Auger metering screw feeder, and fed under a nitrogen purge into and through a multi-temperature zone rotary kiln. The three heated zones of the rotary kiln were each 50.8 cm (20 inches) in length, for a total heated length of 152.4 cm (60 inches). The rotary kiln Zone 1/Zone 2/Zone 3 temperatures were set to 450° C./600° C./800° C. respectively. The speed of the screw feeder was adjusted to between 5 kg of extrudate per hour. The angle of inclination and rotation rate of the rotary kiln were adjusted to maintain a desired residence time in the 152.4 cm (60 inch) heated zone of the kiln. The target average residence time was 60 minutes, while the actual average residence time calculated after the runs was between 53 and 73 minutes, as adjustments were made to target 60 minutes residence time. A nitrogen purge was also applied to both the entrance and exit of the furnace, and to the product collection vessel. The pyrolyzed extrudate was collected in a collection vessel under a nitrogen purge and volatile products that result from the pyrolysis were sent to a cooled collection vessel (for condensables) for downstream waste processing, with off-gases going to an afterburner.

Of the 213.5 kg of dried extrudate material charged to the feeder, 7.6 kg remained in the feeder or feed section of the kiln, thus a total of 205.9 kg of dried extrudate was passed though the kiln. A total of 106.5 kg of pyrolyzed product was collected, for a simple “as is” mass-based yield of 51.7%.

Measurement of residual moisture on a moisture balance (using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample) indicated the continuous-pyrolyzed extrudates had 1.0 wt. % moisture, giving a dry-basis yield of 105.4 kg. Since the dried extrudate starting material for the pyrolysis had a moisture level of 17.7 wt. %, the 205.9 kg of feed represents 187.4 kg on a dry basis, and thus the yield of the pyrolysis on a dry basis is 56.2% (105.4 kg/187.4 kg).

On a dry basis, the dried extrudate starting material for the pyrolysis is 46.9 wt. % carbon black and 53.1 wt. % binder (taking into account the measure moisture content of the extrusion starting materials (measured on a moisture balance using a temperature setting of 160° C. and a time of 30 minutes for a 5 g sample), which were 2.8% for the carbon black, 9.7% for the Dextrose Monohydrate, and 4.7% for the Hydroxyethyl cellulose. Thus, assuming the mass of carbon black is unchanged by the pyrolysis, then on a dry basis the pyrolyzed extrudates have a carbon black content of 83.4 wt. % and a carbonized binder content of 16.6 wt. %.

Table 35 presents the process conditions for the multi-temperature zone rotary kiln. The surface area, pore volume and mean pore diameter, and the crush strength of the resulting pyrolyzed extrudates are shown in Table 36. The crush strengths for the four batches ranged from 14.0 N/mm to 18.4 N/mm, with an average of 15.6 N/mm. This demonstrated that the faster belt drying method used for these examples was as good as the slower methods used in the previous example, and again gave a significant improvement in final (pyrolyzed) extrudate crush strength compared with the Examples that employed continuous belt drying.

TABLE 35 Total Steady Kiln Temperature Residence State Volu- (° C.) Time in the 3 Feed Sample metric Zone Zone Zone Heated Zones Rate Time Feeder Batch 1 2 3 (minutes) (kg/hr) (hours) Type 1 450 600 800 72.6 5 7 Open Helical Auger 2 450 600 800 53.4 5 9 Open Helical Auger 3 450 600 800 60.0 5 9 Open Helical Auger 4 450 600 800 64.3 5 7 Open Helical Auger

TABLE 36 Steady State N₂ BJH Steady State % fines Product after N₂ BJH Adsorption Product before (sieved sieving to N₂ BET Adsorption Mean Pore Radial Piece sieving on 1 mm remove fines Surface area Pore volume Diameter Crush Strength Batch (g) screen) (g) (m²/g) (cm³/g) (Å) (N/mm) 1 17,270 5.6 16.28 175 0.33 148 14.0 2 24,285 7.3 22.49 174 0.34 158 15.9 3 23,528 7.6 21.73 173 0.34 152 14.0 4 17,390 7.3 16.13 178 0.37 161 18.4 Mean 175 0.35 155 15.6 Value

When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above compositions, methods, and processes without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings] shall be interpreted as illustrative and not in a limiting sense.

Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. 

What is claimed is:
 1. A process for preparing a shaped porous carbon product, the process comprising: mixing a carbonaceous material comprising activated carbon and/or carbon black and an organic binder to form a carbon-binder mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and/or (ii) cellulosic compound; forming the carbon-binder mixture to produce a shaped carbon composite; and heating the shaped carbon composite in a heating zone to carbonize the binder thereby producing the shaped porous carbon product, wherein the content of the saccharide and/or cellulosic compound binder(s) in the carbon-binder mixture is from about 20 wt. % to about 65 wt. %.
 2. The process of claim 1 wherein the heating zone comprises at least two heating stages that are each maintained at an approximately constant temperature and the temperature of each stage differs by at least about 50° C., with the temperature increasing from one stage to the next.
 3. The process of claim 2 wherein the temperature of each stage differs by from about 50° C. to about 500° C.
 4. The process of claim 2 wherein the heating zone comprises a multi-stage continuous rotary kiln.
 5. The process of claim 1 wherein the heating zone comprises at least three heating stages that are each maintained at an approximately constant temperature and the temperature of each stage independently differs by at least about 50° C. from the preceding stage.
 6. The process of claim 1 wherein the carbon-binder mixture further comprises a solvent.
 7. The process of claim 6 wherein the process further comprises drying the shaped carbon composite to remove at least a portion of the solvent contained therein.
 8. The process of claim 7 wherein the water content of the shaped carbon composite after drying is in the range of from about 2 wt. % to about 15 wt. %.
 9. The process of claim 7 wherein the heating zone further comprises one or more stages for drying the shaped carbon composite.
 10. The process of claim 7 wherein the heating zone comprises a belt conveyor furnace.
 11. The process of claim 1 wherein the binder comprises: (i) the saccharide selected from the group consisting of a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof and (ii) the cellulosic compound, wherein a 2 wt. % aqueous solution of the cellulosic compound has a viscosity of no greater than about 500 mPa·s at 25° C. and/or the cellulosic compound has a number average molecular weight (M_(n)) that is no greater than about 50,000 g/mol.
 12. The process of claim 1 wherein the shaped carbon composite is heated to a final temperature in the range of from about 400° C. to about 1,000° C. in the heating zone.
 13. The process of claim 1 wherein the shaped carbon composite is formed by extruding the carbon-binder mixture.
 14. The process of claim 1 wherein the weight ratio of binder to carbonaceous material in the carbon-binder mixture is from about 1:4 to about 3:1.
 15. The process of claim 1 wherein the shaped porous carbon product has a radial piece crush strength greater than about 4.4 N/mm (1 lb/mm).
 16. The process of claim 1 wherein the shaped porous carbon product has a mechanical piece crush strength greater than about 22 N (5 lbs).
 17. The process of claim 1 wherein the binder does not comprise a non-carbohydrate synthetic polymer.
 18. The process of claim 1 wherein the carbonaceous material comprises carbon black.
 19. The process of claim 18 wherein the carbon black has a BET specific surface area from about 5 m²/g to about 500 m²/g.
 20. The process of claim 1 wherein the cellulosic compound is selected from the group consisting of methylcellulose, ethylcellulose, ethylmethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, methylhydroxyethylcellulose, ethylhydroxyethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, and mixtures thereof.
 21. The process of claim 1 wherein the cellulosic compound comprises a starch.
 22. The process of claim 1 wherein the binder comprises the saccharide and the cellulosic compound, wherein the saccharide is selected from the group consisting of glucose, fructose or hydrate thereof and the cellulosic compound is selected from the group consisting of hydroxyethylcellulose, methylcellulose, and starch.
 23. The process of claim 22 wherein the content of the saccharide and cellulosic compound binder in the carbon-binder mixture is from about 35 wt. % to about 65 wt. %. 